Ultrasonic Spraying Near‑Infrared Laser Absorber
Ultrasonic Spraying Near‑Infrared Laser Absorber Solution: A Technological Breakthrough in Welding Transparent Plastics
In today’s era of miniaturized electronic devices and precision medical equipment, transparent plastics, with their lightweight, corrosion resistance, and optical properties, have become core materials in many high-end manufacturing fields. However, the natural transparency of these materials to near-infrared lasers in the 940-1100nm wavelength range has made welding a challenging industry problem—traditional welding methods either leave obvious weld marks affecting the appearance or cause material deformation due to uncontrolled heat input, consistently failing to meet the dual requirements of sealing and light transmission. The combined application of near-infrared laser absorber solution and ultrasonic spraying system provides a fundamental solution to this dilemma, propelling transparent plastic welding technology into a new stage of precision and controllability.
The core value of near-infrared laser absorber solution lies in its precise adaptation to the welding scenarios of transparent plastics. Through special molecular structure design, this specialized solution can specifically capture near-infrared laser energy in the 940-1100nm wavelength range without affecting the optical transparency of the plastic substrate itself. When a laser is applied to a welding interface coated with an absorbent solution, the solution molecules rapidly absorb energy and convert it into localized heat, causing the plastic at the interface to melt instantly. Meanwhile, the surrounding areas not in contact with the absorbent remain stable, achieving “precise heating and directional welding” in principle. Compared to traditional methods of adding solid absorbents, the solution-based absorbent integrates more easily with the plastic substrate, avoiding particle agglomeration that reduces light transmittance. The welded product retains over 90% of its original light transmittance, fully meeting the needs of high-end applications such as optical devices and transparent medical shells.
The ultrasonic spraying system provides technical support for the efficient application of the absorbent solution. Its core advantages lie in two dimensions: “precise controllability” and “uniform stability.” This system uses ultrasonic vibrations to atomize the absorbent solution into tiny droplets with a diameter of only a few micrometers. Guided by airflow, these droplets uniformly adhere to the transparent plastic surface, forming a coating with a thickness that can be precisely controlled between 0.1 and 5 micrometers. This refined spraying method completely solves the problems of uneven coating and edge overflow inherent in traditional spraying, forming a continuous and complete absorbent layer even on complex curved surfaces or in small welding areas. More importantly, the atomization process of ultrasonic spraying eliminates the need for high pressure, avoiding material waste caused by solution splashing and increasing coating utilization to over 95%, while significantly reducing pollution to the working environment.
The synergistic application of these two technologies creates a highly efficient and reliable transparent plastic welding solution. In actual production, operators only need to set parameters such as coating thickness and spraying range through the control system. The ultrasonic spraying system then automatically and precisely applies the absorbent solution. Subsequently, the laser equipment scans along a preset trajectory, and the laser energy absorbed by the absorbent layer rapidly melts the interface, forming a strong weld after cooling. This welding method not only increases weld strength by 3-5 times compared to traditional adhesive bonding but also produces no volatile substances throughout the process, fully complying with hygiene standards in fields such as medical and food packaging. In a case study of a micro-electronic sensor production, this solution successfully achieved seamless welding between the transparent shell and the internal structure, with the weld width controlled within 0.2 mm, light transmittance unaffected, and product qualification rate increased from 82% with traditional processes to 99.5%.
With the ever-increasing demands for precision in material joining in high-end manufacturing, the combination technology of ultrasonic spraying and near-infrared laser absorber solution is showing broad application prospects. From welding transparent shells for smart wearable devices to sealing connections in medical infusion sets, and insulating encapsulation for new energy components, this technology not only solves the industry pain points of transparent plastic welding but also drives related products towards thinner, more precise, and more reliable designs, providing strong support for material innovation and process upgrades in the high-end manufacturing field.
About Cheersonic
Cheersonic is the leading developer and manufacturer of ultrasonic coating systems for applying precise, thin film coatings to protect, strengthen or smooth surfaces on parts and components for the microelectronics/electronics, alternative energy, medical and industrial markets, including specialized glass applications in construction and automotive.
Our coating solutions are environmentally-friendly, efficient and highly reliable, and enable dramatic reductions in overspray, savings in raw material, water and energy usage and provide improved process repeatability, transfer efficiency, high uniformity and reduced emissions.
If you have any technical questions, customization demands, or procurement inquiries about ultrasonic atomization nozzles, feel free to contact our professional sales and technical team for detailed parameters, customized solutions, and industry application support.
Email: market2@cheersonic.com
