Impulse Welding

Impulse welding is the process by which electricity is used to create heat through a high resistance wire. The wire is typically nickel-chromium encapsulated in a non-stick coating. A current will cause the wire to heat rapidly which is transferred to the materials. Traditional impulse welding processes have limited controls over the heating and cooling cycles. This results in a continuous heat build-up as the machine cycles, negatively effecting the repeatability of subsequent welds.

Zemat TG has developed a proprietary system with a closed loop feedback that enables control over the entire weld cycle. The process automatically compensates for variables in the materials, environment, and current fluctuations thus delivering an accurate and repeatable target temperature. We continue to apply this process to new engineered materials that cannot be traditionally HF or constant heat welded.

Advantages of Impulse Welding Technology

  • Impulse seal is ready to use: This is no warm-up period after turning it on.
  • Impulse seal is economical: Electricity for the heater is only used during the sealing process.
  • Impulse seal poses little risk of burn injury: No component is always hot.
  • Impulse seal creates a seal with a clean slate:Cooling and fusion takes place under pressure.
  • Constant heat sealer requires waiting time for the hot bar to heat up. This also means additional power is wasted.
  • Constant heat sealer must maintain the sealing bar hot at all times. Power is constantly drained as long as the switch is on.
  • Constant heat sealer maintains the sealing area hot at all times, exposing the user to a higher risk of accidentally touching the hot bar.
  • Constant heat sealer merely provides heat, leaving cooling and fusing process to take place while the package material is shrinking. This results in a rather uneven finish.