Welding method and apparatus using infrared radiation

Abstract: A filter (28) for absorbing electromagnetic radiation which is used in heating a welding zone wherein a first part (24) is joined to a second part (26). The filter (28) includes a solid material (36,38) for absorbing undesired wavelengths of radiation from a heating source (20) before the radiation reaches the welding zone (27). The filter (28) also has a housing which contains a chamber (34) within which a fluid (42) is placed. The fluid (42) cools the solid material and also may absorb undesired wavelengths of radiation from the heating source (20) before the radiation reaches the welding zone (27). A heat exchanger (30) is connected to the filter (28) in order to cool the fluid (42) during the filtering process.

Description: The present invention concerns a filter for filtering electromagnetic radiation used to heat a welding zone and a method for filtering electromagnetic radiation used to heat a welding zone. The present invention relates generally to welding. It relates more particularly to an improved method and apparatus for welding plastics and like materials utilizing electromagnetic radiation. Welding is commonly used to join plastic or resinous parts, such as automobile thermoplastic parts, at a welding zone. Lasers have been used to provide the heat necessary to perform the welding operation (for example, see US-A- 4,636,609 Lasers provide a focused beam of electromagnetic radiation at a specified frequency (i.e., coherent monochromatic radiation). However, lasers tend to be more expensive relative to other heating sources. The WO-A-96/40517 describes a joining method directing polychromate, non-coherent electromagnetic radiation (14) through a radiation transmitting material to an absorbing material that absorbs the radiation with the generation of heat. The heat is used to heat a bond line formed from the transmitting material and a substrate sufficiently to bond the transmitting material and substrate. A radiation filter of the same material as the transmitting material is used to reduce effectively unwanted absorption (and heat) in the transmitting material. The EP 0 485 864 discloses an irradiation device comprising a water filter for heat therapy. That water filter absorbs radiations, which are harmful to the human bodies. The device is not used in the field of the welding technique. Less expensive heat producing sources, such as infrared heating lamps, are also used to provide infrared radiation for heating the welding zone. One such process is Through-Transmission Infrared Welding (TTIR). The TTIR technique utilizes infrared radiation which passes through at least one plastic part (sometimes called the "transmission piece") in order to heat the welding zone in at least one other piece and to provide sufficient heat to join at least two parts. Infrared heating lamps emit noncoherent radiation which typically has a much broader frequency range (i.e., polychromatic) than laser sources. Some of the frequencies within that broader range produce undesirable results. These undesirable results include heating portions of the parts beyond the desired or targeted welding zone. This can result in turn in undesirable effects, including deformation and marking of the overall part. Solid materials have been used to selectively filter or absorb these undesirable frequencies before the radiation reaches the target parts. However, solid filters suffer from several disadvantages, including uncontrolled build-up of heat, as well as having to be continually replaced due to the damage or degradation caused by the radiation or heat by-product. The degradation of the solid filter over a period of time inhibits the performance of the solid filter to absorb the undesirable wavelengths. It is also difficult to adequately cool solid filters in many applications with such present technology as blowing cool air upon the solid filters. The welding apparatus of the present invention is defined in the characterizing portion of claims 1, 56, 59 and 62 and the welding method of the present invention is defined in the characterizing portion of claims 24 and 65. A primary object of the present invention includes providing an improved welding apparatus and method utilizing a filter or filter system of unique design which obviates the disadvantages of the aforementioned prior filters and is less costly. Several embodiments of the invention are disclosed. Additional advantages and features of the present invention will become apparent to the skilled artisan from the subsequent description and the appended claims, taken in conjunction with the accompanying drawings in which: Figure 1 is a diagrammatic perspective view depicting an apparatus employing the present invention; Figure 2a is a side view depicting an alternate embodiment of the present invention; and Figure 2b is a top view depicting an alternate embodiment of the present invention. Referring to Figure 1, there is disclosed a welding apparatus according to the present invention comprising a radiant heating lamp 20 which emits noncoherent polychromatic electromagnetic radiation 22 in order to weld a first part 24 to a second part 26 at welding zone 27 . A uniquely designed filter 28 is disposed between the radiant heating lamp 20 and the first part 24 to absorb undesired wavelengths included in radiation 22 . A heat exchanger 30 is provided to maintain filter 28 within a desired temperature range while filter 28 is in use. Filter 28 includes a housing 32 having a chamber 34 defined by a first plate 36 and a second plate 38 , the first and said second plates being generally parallel (if flat as shown), and a peripheral seal 40 disposed therebetween. First plate 36 and second plate 38 filter part of radiation 22 emanating from radiant heating lamp 20 by absorbing substantially all of the undesired wavelengths of radiation 22 before it can reach first part 24. The filtering produces filtered radiation 44 . Optionally, a clamp (not shown) can be used to maintain the structural integrity of the housing 32 by clamping the first plate 36 to the second plate 38. In accordance with the present invention, chamber 34 contains a cooling or cooling/filtering fluid 42 which cools first plate 36 and second plate 38 . However, in the preferred embodiment, fluid 42 also filters part of radiation 22 emanating from radiant heating lamp 20 to produce filtered radiation 44 . In a TTIR application, the first part 24 transmits the filtered radiation 44 to welding zone 27 . The filtered radiation 44 heats the welding zone 27 in order to weld first part 24 to second part 26 . Significantly, the absorption of the undesired wavelengths by filter 28 allows welding zone 27 to be adequately heated without the filtered radiation 44 causing overall damage to or undesired effects in first part 24 or second part 26 . The present invention includes at least one of the plates being used as a solid filter, providing some or all of the filtering function. For example, first plate 36 and second plate 38 may be of substantially the same material as first part 24 (or at least the plates should have substantially the same absorption profile as first part 24 ). Accordingly, if first part 24 is a polycarbonate plastic part, then first plate 36 and second plate 38 are also polycarbonate plastic parts. Moreover, fluid 42 may act as a cooling or heat transfer agent, or it may preferably act as both a partial filter and as a cooling or heat transfer agent. The following may be used in determining the thicknesses of the plates ( 36 and 38 ): the particular application; the intensity of the radiation 22 from the radiant heating lamp 20 ; whether fluid 42 is acting as a filtering fluid; and whether both plates ( 36 and 38 ) are being used to filter. It will be appreciated by the skilled artisan that the composition selection of the first plate 36 and second plate 38 and fluid 42 will generally be dependent upon several factors, most importantly its ability to absorb the undesired or harmful wavelengths of the radiation 22 employed in the particular application. For example, in at least one preferred embodiment, first plate 36 and second plate 38 and fluid 42 should absorb the wavelengths of radiation 22 in the range from 1 to 5 µm (1 to 5 microns) for welding conventional thermoplastic polymeric materials. More preferably, they should absorb the wavelengths of radiation 22 in the range from 1.3 to 4 µm (1.3 microns to 4 microns) for welding such polymeric materials. Conventional polymeric materials which are particularly useful for welding by the practice of the present invention are preferably selected from the thermoplastic class of materials. These materials can be categorized in several ways. The preferred materials are generally classified as engineering thermoplastics (ETPs); they are also sometimes classified as thermoplastic elastomers (TPEs); thermoplastic polyolefins (TPO); and thermoplastic polyurethanes (TPUs). This would include such materials as polycarbonates, high heat polycarbonates, polycarbonate blends (e.g., polyurethane/polycarbonate blends), styrenes, styrene blends such as acrylonitrile-butadiene-styrene copolymers (ABS), polycarbonate/ABS blends, polyamides, polyamide blends, acrylic-styrene-acrylonitriles (ASAs); acrylonitrile-ethylene-propylene-styrenes (AEWS), styrene-acrylonitrilecopolymer, styrene-maleic anhydrides, and the like. In a highly preferred embodiment, they include (without limitation) such materials as polycarbonates, acrylics, and polystyrene materials. Fluid 42 is preferably a liquid which should have a relatively high boiling point. The relatively high boiling point allows fluid 42 to absorb a significant amount of heat and also to not evaporate or boil during the filtering process. Fluid 42 should have a boiling point (with pressure considerations being taken into account with respect to the following boiling points) of at least about 50°C (120°F), more preferably at least about 116°C (240°F), and ideally at least about 177°C (350°F), either under atmospheric conditions, or when contained in the chamber or system. When fluid 42 acts as both a partial filter and as a cooling or heat transfer agent in the preferred embodiment, the preferred cooling/filtering fluid is a mixture of liquids comprising dimethyl esters of glutaric, adipic, and succinic acids. Such a dimethyl ester mixture is available commercially and may be obtained from such sources as Du Pont under the tradename of Aliphatic Dibasic Esters; such materials are also known under the tradenames/synonyms of Dibasic Ester, Dibasic Ester Mixture, and DBF. Such materials are generally mixtures of materials of the formula CH 3 COO(CH 2 ) n COOCH 3 , wherein n is an integer value from 1 to 5, more preferably from 2 to 4. In a highly preferred embodiment, the fluid 42 is a mixture comprising about 55-75 percent (by weight) of dimethyl glutarate, about 10-25% dimethyl adipate, and about 19-26% dimethyl succinate. Other examples of useful materials employed when the fluid is primarily employed as a cooling fluid or agent include materials which transmit (do not absorb) the radiation that is desired to effect the welding. These include materials selected from the group consisting of glycerol, ethylene-glycerol, dioctyl phthalate, tributyl phosphene, mineral, and mixtures or derivatives of these materials. However, it is to be understood that the present invention is not limited to this fluid nor to fluids of these absorption wavelengths or boiling points, but includes other fluids, such as but not limited to gas compositions, whose physical characteristics are sufficient to filter undesirable radiation from any heating source used in a welding operation for any appropriate material. Additives may also be employed in the cooling or cooling/filtering fluid so long as they do not substantially degrade the absorption profile of the liquid in any materially adverse way. For example, viscosity modifiers, thermal and UV stabilizers, colorants, pigments, visual indicators, and the like may be employed. When fluid 42 acts only as a cooling or heat transfer agent in the present invention, fluid 42 may be a liquid containing 1, 2, 3, 4, 5, 5-hexachloro-1,3-cyclopentadiene with a molecular weight of about 272.77 and a boiling point of between about 235 degrees Celsius and 238 degrees Celsius which may be obtained from such sources as Aldrich Chemical Company, Inc. Generally, the liquid should be substantially free from hydrocarbon absorptions or similar absorption profiles. Accordingly, organic fluids whose hydrogen atoms have been displaced in whole or in part by halogen atoms are preferred. Moreover, if the fluid is a liquid within this embodiment it may comprise water. It is to be understood that the present invention within this embodiment is not limited to liquids of this composition but includes those liquids which provide adequate cooling to the absorbing plates while absorbing little of the radiation themselves. A heat exchanger 30 is connected in fluid communication to filter 28 in order to cool fluid 42 while filter 28 is absorbing the undesired wavelengths from radiation 22 . Pump 46 is preferably disposed in a supply line 48 between chamber 34 and heat exchanger 30 . The present invention also includes other techniques besides using pump 46 to transport fluid 42 between chamber 34 and heat exchanger 30 , such as but not limited to, transportation of fluid 42 through standard convection techniques. A return line 50 returns the cooled fluid to chamber 34 . Any conventional heat exchanger 30 and pump 46 may be used in accordance with standard practices. During the filtering operation, heat exchanger 30 preferably maintains fluid 42 at a predetermined temperature range, e.g., preferably a range that would include from 18°C to 50°C (65°F to 120°F). The continual removal of heated fluid from filter 28 with the resupply of cooled fluid into filter 28 provides filter 28 with a longer operational life than that experienced by known solid filters. In a preferred embodiment, fluid 42 is contained in chamber 34 which has the following dimensions : 0.64cm by 30.5cm by 0.32cm (one-fourth inches by twelve inches by one-eighth inches). However, it is to be understood that the dimensions of chamber 34 varies according to the particular application. Also in a preferred embodiment, about one-hundred percent of chamber 34 was filled with the Dibasic Ester fluid from Du Pont. Additionally, in a preferred embodiment, radiant heating lamp 20 is an ELC 250 watt 24 volt ac quartz-halogen General Electric reflector lamp, having either a multilayer dichroic coating for selectively reflecting preferred wavelengths, or an aluminized coating for reflecting relatively all visible and infrared radiation from the quartz-halogen source. Figures 2a and 2b illustrate a side view and a top view respectively of an alternate embodiment for filter 28 . Referring to Figure 2a, housing 32 defines a chamber 34 which contains a solid material 54 . Solid material 54 is transparent to the welding energy or radiation of interest and absorbs predetermined wavelengths of the radiation before the radiation reaches the welding zone. The radiation enters filter 28 through a top plate 56 and is filtered by solid material 54 before exiting filter 28 through a bottom plate 58 . Moreover, solid material 54 is cooled by a fluid which enters chamber 34 through return line 50 and exits chamber 34 through supply line 48 . As disclosed above, the fluid may act as a cooling or heat transfer agent, or it may preferably act as both a partial filter and as a cooling or heat transfer agent. Top plate 56 and bottom plate 58 are generally parallel or equidistant from each other. Top plate 56 and bottom plate 58 are preferably quartz plates which are obtainable from such sources as Quartz Scientific, Inc. These quartz plates have thicknesses of about 0,32 cm (one-eighth of an inch) and are separated (or spaced) by a distance sufficient to accommodate solid material 54 and to allow adequate cooling of solid material 54 by the fluid. It is to be understood, however, that the present invention is not limited to only quartz plates or to these dimensions or shapes. The present invention includes such other embodiments as those plates which transmit substantially all of the wavelengths of the radiation from a radiant heating lamp. Moreover, another alternate embodiment of the present invention includes at least one of the plates ( 56 or 58 ) being made of material functionally equivalent to solid material 54 in order to provide additional filtering capability. Referring to Figure 2b, solid material 54 is connected through conventional techniques (e.g., glued or bolted) to sides 60 of housing 32 for support. However, it is to be understood that the present invention in this alternate embodiment is not limited to solid material 54 being supported only at sides 60 of housing 32 , but includes such other support mechanisms as will allow solid material 54 to be supported within housing 32 while still allowing solid material 54 to adequately absorb the predetermined wavelengths of the radiation. EXAMPLE Referring back to Figure 1, the present invention is specially wellsuited for the TTIR welding of a first plastic part to a second plastic part. In one exemplary use of the present invention, first part 24 is a transmitting plastic 24 which is to be welded to second part 26. Transmitting plastic 24 has the characteristic of absorbing little of the filtered radiation 44 as it transmits the filtered radiation 44 to the welding zone 27 . For this example, transmitting plastic 24 and second part 26 may be polycarbonate plastic parts. According to a preferred embodiment, an absorbing material 52 is placed in welding zone 27 to generate heat upon the filtered radiation 44 reaching the welding zone 27 . Sufficient heat is generated by the absorbing material 52 so as to weld the transmitting plastic 24 to the second part 26 . The absorbing material 52 contained carbon black; however, other absorbing materials can be used which would generate sufficient heat to weld the parts. For this example, the radiant heating lamp 20 was operated in the following manner (with filter 28 in place) in order to weld the transmitting plastic 24 to the second part 26 : radiant heating lamp 20 was operated at eighty percent to ninety percent of its rated voltage level to heat the absorbing material 52 (a ramp time of one-half to one second was used); radiant heating lamp 20 remained at that level between six to nine seconds; and radiant heating lamp 20 was operated at between five percent to thirty percent of its rated voltage level during the idle portions of the welding cycle. Operation of radiant heating lamp 20 in the aforementioned manner substantially increased the useful life of the radiant heating lamp 20 . However, it is to be understood that the present invention is not limited to these operational ranges. The operational ranges may vary depending upon the particular radiant heating lamp 20 used and the parts to be welded. For example, the present invention includes operating radiant heating lamp 20 within a voltage range which has a lower limit of about sixty percent of the voltage level rating of the radiant heating lamp 20 . With respect to TTIR applications, first plate 36 and second plate 38 and fluid 42 employed in the preferred embodiment are materials whose absorption properties or profile are as close as possible to the transmitting plastic 24 . In some instances, it may be possible to use a prepolymer comprising one or more of the same monomers as the transmitting plastic 24 . Further, suitable derivatives of the monomers may be employed. Additionally, first plate 36 and second plate 38 and fluid 42 employed in the preferred embodiment transmit those wavelengths of the radiation 22 which are needed by the absorbing material 52 to heat welding zone 27. Additionally, the present invention also includes those TTIR applications wherein the second part 26 itself contains absorbing material 52 at least sufficiently near to the welding zone 27 so as to generate the heat needed to weld the transmitting plastic 24 to the second part 26 . The embodiments which have been set forth above were for the purpose of illustration and were not intended to limit the invention. For example, the present invention is not limited to only welding applications, but includes those applications where filtering of undesired wavelengths is desired. Moreover, it will be appreciated by those skilled in the art that various changes and modifications may be made to the embodiments discussed in the specification without departing from the scope of the invention as defined by the appended claims.

Claims: A filter (28) for filtering electromagnetic radiation used to heat a welding zone (27) characterized in comprising: a solid material (36,38) for absorbing predetermined wavelengths of said radiation before said radiation reaches said welding zone (27), a housing (32) which defines a chamber (34); and a fluid (42) disposed in said chamber (34) for cooling said solid material (36,38) wherein said housing (32) transmits filtered electromagnetic radiation to said welding zone (27). The filter (28) according to claim 1 characterized in that said housing (32) includes a first (36) and second (38) plate defining said chamber (34), said solid material being used at least as one of said plates (36,38). The filter (28) according to claim 2 characterized in further comprising a second solid material (54) contained within said chamber (34) for absorbing said predetermined wavelengths of said radiation before said radiation reaches said welding zone (27). The filter (28) according to claim 1 characterized in that said housing (32) includes a first and second plates (36,38) defining said chamber (34), said first and second plates (36,38) transmitting substantially all wavelengths of said radiation. The filter (28) according to claim 4 characterized in that said solid material (54) is contained within said chamber (34) . The filter (28) according to claim 1 characterized in that first and second plates (36,38) are quartz plates sealed together to form said chamber (34). The filter (28) according to claim 1 characterized in further comprising: a heat exchanger (30) in fluid communication with said housing (32) for reducing the temperature of said fluid (42); and pump means (46) connected to said housing (32) and to said heat exchanger (30) for pumping said fluid (42) between said housing (32) and said heat exchanger (40). The filter (28) according to claim 7 characterized in that said pump means provides continuous removal of heated fluid from said housing (32) and resupply of cooled fluid from said heat exchanger (30). The filter (28) according to claim 1 characterized in that said fluid (42) is a liquid, said liquid having a boiling point above about 50°C (120°F). The filter (28) according to claim 9 characterized in that said liquid is an organic compound with at least one halogen atom being substituted for a hydrogen atom on said organic compound. The filter (28) according to claim 1 characterized in that said fluid absorbs substantially all predetermined wavelengths of said radiation before said radiation reaches said welding zone (27). The filter (28) according to claim 11 characterized in that said absorbed predetermined wavelengths of said radiation includes wavelengths of radiation above at least 1 µm (1 micron). The filter (28) according to claim 12 characterized in that said absorbed predetermined wavelengths of said radiation includes radiation from at least 1.2 µm to 4 µm (1.2 microns to 4 microns). The filter (28) according to claim 1 characterized in that said fluid is selected from the group consisting of glycerol, ethylene-glycerol, dioctyl phthalate, tributyl phosphene, mineral, and mixtures or derivatives of these materials. The filter (28) according to claim 1 characterized in that said fluid is a mixture of liquid, said liquid being dimethyl esters of glutaric, adipic and succinic acids. The filter (28) according to claim 1 characterized in that the wavelenghts of said radiation are substantially within the infrared electromagnetic spectrum. The filter (28) according to claim 1 characterized in that said radiation is produced from a radiant heating lamp (20). The filter (28) according to claim 1 characterized in that said welding zone (27) defines an area for welding a first (24) and second (26) plastic part, said first part (24) transmitting substantially all wavelengths of said radiation. The filter (28) according to claim 18 characterized in that said second part (26) absorbs second predetermined wavelengths of said radiation. The filter (28) according to claim 18 characterized in that said welding zone (27) includes an absorbing material (52) which is heated by said filtered radiation in order to weld said first and second part (24,26). The filter (28) according to claim 18 characterized in that said radiation is produced from a radiant heating lamp (20), said filter (28) further comprising: a heat exchanger (30) in fluid communication with said housing (32) for reducing the temperature of said fluid. The filter (28) according to claim 17 characterized in that said solid material (36,38) is substantially the same material as said first part (24). The filter (28) according to claim 1 characterized in that said solid material (36,38) is substantially motionless in said fluid while said solid material (36,38) absorbs said predetermined wavelengths of said radiation. A method for filtering electromagnetic radiation used to heat a welding zone (27), comprising the steps of: emitting said radiation from a heating source (20); characterized in absorbing predetermined wavelengths of said radiation by a solid material (36,38) to produce filtered radiation; cooling said absorbing solid material (36,38) with a fluid (42) said fluid (42) being disposed in a chamber (34) of a housing (32); and providing said filtered radiation to said welding zone (27) said housing (32) transmitting said filtered electromagnetic radiation to said welding zone (27). The method according to claim 24 characterized in further comprising the step of: absorbing the predetermined wavelengths of said radiation by said fluid (42) to produce said filtered radiation. The method according to claim 25 characterized in further comprising the step of: cooling said fluid. The method according to claim 26 characterized in further comprising the step of: providing a heat exchanger (30) for reducing the temperature of said fluid (42). The method according to claim 27 characterized in further comprising: pumping said fluid (42) to said heat exchanger (30). The method according to claim 24, characterized in that said housing (32) includes first and second plates (36,38) defining said chamber (34), said solid material being used at least as one of said plates (36,38). The method according to claim 29, characterized in that a second solid material (54) is contained within said chamber (32) for absorbing said predetermined wavelengths of said radiation to produce said filtered radiation. The method according to claim 24, characterized in that said housing (32) includes first and second plates (36,38) defining said chamber (34), said first and second (36,38) plates transmitting substantially all wavelengths of said radiation. The method according to claim 31, characterized in that said solid material (54) is contained within said chamber (34). The method according to claim 31, characterized in that said first and second plates (36,38) are quartz plates sealed together to form said chamber (34). The method according to claim 24, characterized in that said fluid (42) is a liquid, said liquid having a boiling point above 50°C (120°F). The method according to claim 34, characterized in that said liquid is an organic compound with at leat one halogen atom being substituted for a hydrogen atom on said organic compound. The method according to claim 24, characterized in that said fluid is a liquid which absorbs predetermined wavelengths of said radiation before said radiation reaches said welding zone. The method according to claim 36, characterized in that said absorbed predetermined wavelengths of said radiation includes wavelengths of radiation above at least 1 µm (1 micron). The method according to claim 37 characterized in that said absorbed predetermined wavelengths of said radiation includes radiation from at least 1.2 µm to 4 µm (1.2 microns to 4 microns). The method according to claim 38 characterized by said liquid being dimethyl esters of glutaric, adipic and succinic acids. The method according to claim 24 characterized in that the wavelenghts of said radiation are substantially within the infrared electromagnetic spectrum. The method according to claim 24 characterized in that said radiation is produced from a radiant heating lamp (20) . The method according to claim 24 characterized in that said welding zone (27) defines an area for welding a first (24) and second (26) plastic part, said first part (24) transmitting substantially all wavelengths of said filtered radiation. The method according to claim 42 characterized in that said second part (26) absorbs second predetermined wavelengths of said radiation. The method according to claim 42 characterized in that said welding zone (27) includes an absorbing material (52) which is heated by said filtered radiation in order to weld said first and second parts (24,26). The method according to claim 42 characterized in that said radiation is produced from a radiant heating lamp (20), said method further comprising the step of: providing a heat exchanger (30) for reducing the temperature of said fluid (42). The method according to claim 24 characterized in that said solid material (36,38) is substantially the same material as said first part (24). The method according to claim 24 characterized in that said solid material (36,38) is substantially motionless in said fluid while said solid material (36,38) absorbs said predetermined wavelengths of said radiation. The method according to claim 44 characterized in that said radiation is produced from a radiant heating lamp (20), said method further comprising the step of: providing a heat exchanger (30) for reducing the temperature of said fluid (42). The method according to claim 42 characterized in that said radiation is produced from a radiant heating lamp (20), said radiant heating lamp (20) having a predetermined voltage level rating, said method further comprising the step of: operating said radiant heating lamp (20) at a first predetermined range in order to heat said welding zone (27), said first predetermined range having a lower limit of about sixty percent of said predetermined voltage level rating. The method according to claim 49 characterized in that said first predetermined range is from about seventy percent of said predetermined voltage level rating to about ninety percent of said predetermined voltage level rating. The method according to claim 24 characterized in that said radiation is produced from a radiant heating lamp (20), said radiant heating lamp (20) having a predetermined voltage level rating, said method further comprising the step of: operating said radiant heating lamp (20) at a first predetermined range in order to heat said welding zone (27), said first predetermined range having a lower limit of about sixty percent of said predetermined voltage level rating. The method according to claim 24 characterized in further comprising the step of: providing a ramp time of between 0.5 to 1 seconds to reach said first predetermined range for said radiant heating lamp. The method according to claim 24 characterized in that said radiation is produced from a radiant heating lamp (20), said radiant heating lamp (20) being operated according to steps (a)-(c): (a) operating said radiant heating lamp at a first predetermined range in order to heat said welding zone (27), said first predetermined range having a lower limit of about sixty percent of said predetermined voltage level rating; (b) idling said radiant heating lamp at a second predetermined range, said second predetermined range having a lower limit of about five percent of said predetermined voltage level rating; and (c) operating said radiant heating lamp at said first predetermined range in order to heat said welding zone (27), wherein step (c) is performed subsequent to step (b). The method according to claim 53 characterized in that said second predetermined range has an upper limit of about thirty percent of said predetermined voltage level rating. The method according to claim 53 characterized in further comprising the step of: providing a ramp time of between 0.5 to 1 seconds to reach said first predetermined range for said radiant heating lamp. A filter (28) for filtering electromagnetic radiation used to heat a welding zone (27) characterized in comprising: a housing (32) which includes a first (36) and second plate (38) for defining a chamber (34) wherein at least one of said plates (36,38) absorbs predetermined wavelengths of said radiation before said radiation reaches said welding zone (27); and a fluid (42) disposed in said chamber (34) for cooling said solid material said housing transmitting the filtered electromagnetic radiation to said welding zone (27). The filter (28) according to claim 56 characterized in that said fluid (42) absorbs substantially all predetermined wavelenghts of said radiation before said radiation reaches said welding zone (27). The filter (28) according to claim 56 characterized in further comprising: a heat exchanger (30) in fluid communication with said housing (32) for reducing the temperature of said fluid (42). A filter (28) for filtering electromagnetic radiation used to heat a welding one (27) characterized in comprising: a housing (32) which defines a chamber (30); a solid material (54) disposed within said chamber (34) for absorbing predetermined wavelengths of said radiation before said radiation reaches said welding zone (27); and a fluid (42) disposed in said chamber (32) for cooling said solid material said housing transmitting said filtered electromagnetic radiation to said welding zone (27). The filter (28) according to claim 59 characterized in that said fluid (42) absorbs substantially all predetermined wavelenghts of said radiation before said radiation reaches said welding zone (27). The filter (28) according to claim 59 characterized in further comprising: a heat exchanger (30) in fluid communication with said housing (32) for reducing the temperature of said fluid (42). A filter (28) for filtering electromagnetic radiation used to heat a welding zone (27) characterized in comprising: a housing (32) which includes a first (56) and second (58) plate for defining a chamber (34) wherein at least one of said plates (56,58) absorbs predetermined wavelengths of said radiation before said radiation reaches said welding zone (27); a solid material (54) disposed within said chamber (34) for absorbing predetermined wavelengths of said radiation before said radiation reaches said welding zone (27); and a fluid (40) disposed in said chamber (34) for cooling said plate (56,58) and said solid material (54), said housing transmitting said filtered electromagnetic radiation to said welding zone (27). The filter (28) according to claim 62 characterized in that said fluid (42) absorbs substantially all predetermined wavelenghts of said radiation before said radiation reaches said welding zone (27). The filter (28) according to claim 62 characterized in further comprising: a heat exchanger (30) in fluid communication with said housing (34) for reducing the temperature of said fluid (42). A method of heating a welding zone (27) comprising the steps of: emitting electromagnetic radiation from a heating source (20) toward said welding one (27) characterized in absorbing predetermined wavelengths of said radiation by a solid material (54) prior to said radiation reaching said welding zone (27); cooling said absorbing solid material (54) with a liquid, a housing (32) transmitting said filtered electromagnetic radiation to said welding zone (27). The method according to claim 65 characterized in that said liquid (42) is disposed in a chamber (34) of a housing (32). The method according to claim 65 characterized in further comprising the step of: providing a heat exchanger (30) for reducing the temperature of said liquid (42).

Inventors: GREWELL DAVID A, LOVETT DONALD C, GREWELL DAVID A., LOVETT, DONALD C.
Applicants: EMERSON ELECTRIC CO, EMERSON ELECTRIC CO.
Application year: 1998
Main classification: G02F1
IPC codes: B29C35, B29C65