Thermal Press – A Brief Overview
Thermal Press Assembly Processes & Solutions:
- Applications for Thermal Press Assembly Equipment & Solutions
- Thermal Press Machines, Solutions & Systems
Applications for Thermal Assembly:
Heat Staking Applications:
There are many applications for thermal assembly and the associated production equipment and systems required. We are going to outline some of the most common applications and processes, which comprise of the majority of Thermal Press Systems installed worldwide.
Heat Staking Applications for Telecom:
Heat staking is used in Telecommunication, Portable Electronics, and the Tablet market for attaching PCBs, GPS antennas, camera modules, internal components, ground planes and many other functions required in todays handheld and portable electronics devices.
Heat Staking Applications for Automotive Electronics:
Heat staking is used in Automotive and Automotive Electronics market for attaching PCBs, Electronic Harnesses, Flex Circuits, HVAC Electronics, HVAC Ducting, Trim Assemblies (internal and external), as well as many other assembled sub-assemblies used in the manufacturing of vehicles.
Heat Staking Applications for Automotive Lighting:
Heat staking is used in Automotive and Automotive Electronics market for attaching PCBs, Electronic Harnesses, Flex Circuits, HVAC Electronics, HVAC Ducting, Trim Assemblies (internal and external), as well as many other assembled sub-assemblies used in the manufacturing of vehicles. Many applications for heat staking are to eliminate adhesives or screws.
Heat Staking Applications for Bus bars & Fuse blocks:
Heat staking is used to attach metal into plastics for bus bars and fuse blocks in automotive and consumer electronics.
Thermal Insertion Applications for Threaded Inserts:
Similar in concept to Heat staking is the Thermal Insertion process. Thermal Insertion is used to insert threaded metal inserts into plastics covers and bezels to allow for easy assembly and disassembly of consumer electronics. With the Thermal Insertion process multiple inserts of varying sizes and on multiple planes can be inserted into the plastic in one machine cycle, which is an advantage when compared with ultrasonic welding processes used for these complex applications.
Heat Sealing Applications for Medical:
Heat Sealing is used to attach medical ports, fitments, patches, filter and test media into or onto plastic parts and films for many medical devices and medical test applications. These are some of the assemblies using Thermal Press equipment and solutions in the medical device manufacturing industry in production globally.
Heat Seal Connector Applications:
Heat Seal Connectors are commonly used in electronic devices to attach an LCD to a PCB. The Heat Seal process is used in conjunction with detailed and accurate fixturing to allow the heat seal connectors to be aligned and attached. HSC are used much more in the last few decades versus “Zebra” connectors, which require a rugged mechanical assembly design and more complex assembly processes. These programs often require vision systems to aid or automate the alignment processes.
Hot Bar Solder Reflow Applications:
Very similar in process is the Hot Bar –Solder Reflow application. A Hot Bar is used to come down and solder a flex circuit or connector to a PCB or another Flex Circuit. This process is used in electronic devices to attach multiple electronic circuits or flex connectors within a device or electrical system. The Hot Bar process is used in conjunction with detailed and accurate fixturing to allow the traces of the Flex Circuit to be aligned and attached.
Thermal Press Machines, Systems & Solutions:
C-Series Thermal Press
The C-Series Thermal Press (Models C25/C50) are our most popular Thermal Press series for all small to medium size applications (i.e. heat staking, heat sealing, medical port sealing, film-filter sealing, heat seal connectors, thermal insertion, hot bar, etc.,,). The C-Series lends itself well to many tooling and part handling options. Complete digital control via HMI touchscreen with Recipe storage and programmable process alarms. It is fully self-contained and can easily sit on most work benches or tables.
3 year warranty. Options Available.
Specifications: 120VAC (15AMP Max) or 240VAC (30 AMP MAX), 50/60Hz, Single-phase. C25 rated @ 20-400 lbs. Force, C50 rated @ 250-1000 lbs.
H-Series Thermal Press
The H-Series (Model H50/H100) provides higher forces for larger applications without sacrificing any flexibility regardless of the application (i.e. heat staking, heat sealing, medical port sealing, film-filter sealing, heat seal connectors, thermal insertion, etc.,,). The stout “HFrame” design can maintain planarity between the thermal tooling and the part holding fixturing, even under extreme forces! Complete digital control via HMI touchscreen with Recipe storage and programmable process alarms. It is fully self-contained and can easily sit on most work benches or tables.
3 year warranty. Options Available.
Specifications: 120VAC (15AMP Max) or 240VAC (30 AMP MAX), 50/60Hz, Single-phase.
MicroLAB Thermal Press
The MicroLAB Thermal Press series has all of the features of our larger production systems in a very small footprint. Perfect for small size applications. The MicroLAB is completely configurable with a multitude of tooling and actuation packages. The MicroLAB is fully self-contained and is designed for Clean Room and small laboratory environments.
3 year warranty.
Specifications: 120VAC (15AMP Max), 50/60Hz, Single-phase.
*Force and actuation ratings are application and tooling specific
WorkStation and Multi-Cell Thermal Press Systems
The WorkStation Thermal Press Systems (Models WSM25/WSM50) are engineered to be robust and easy to integrate machines/thrusters into any automated production line or as standalone pieces of multi-operation assembly equipment or “workcells”.
The WorkStation Thermal Press Systems feature easy to integrate Thruster-based machines with XY alignment mount bases. They are based upon our popular open-format C-Series machines and have a shared common controller. These Multi-WorkStation systems have all of our standard quick-change tooling and part handling options available. 3 year warranty
Specifications: 120VAC (15AMP Max) or 240VAC (30 AMP MAX), 50/60Hz, Single-phase.
WSM25 rated @ 20-400 lbs. Force, WSM50 rated @ 250-1000 lbs. Force
SMEMA Conveyor Thermal Press System
The SMEMA Conveyor Thermal Press System features our H-Series Thermal Press integrated with conveyor to allow for a completely scalable solution. An excellent solution for the rapid implementation of new equipment into existing SMEMA-compliant work cells.
The SMEMA Conveyor H-Series accommodates the higher forces for larger applications without sacrificing any flexibility. Does not require an operator, while the parts are assembled on the “Pallets” as they pass through the conveyor line.
Our systems can include any manufacture of SMEMA Conveyor or can be designed upon existing conveyor lines to allow for the maximum ease in integration of these systems.
Specifications: 120VAC (15AMP Max) or 240VAC (30 AMP MAX), 50/60Hz, Single-phase.
Dual C-Series Thermal Press (Medical Port Sealer)
The Dual C-Series Thermal Press (Model DC25MM/DC50MM) are customized standards of the raditional C-Series Thermal Press series for large format applications. It is an excellent choice for large sealing applications, such as Port Sealing for Medical Industries and Textile sealing for Automotive and consumer Product Industries. The Dual C-series features a wide-open workspace, with a dual “C-Frame” construction to allow for maximum clearance.
The Dual C-series machines utilize all of the standard tooling, roll feed systems and part handling options that are available with our other lines of machines. Like all of our Thermal Press systems, it is fully self-contained and is on its’ own machine base/cart. 3 Year Warranty.
Specifications: 120VAC (15AMP Max) or 240VAC (30 AMP MAX), 50/60Hz, Single-phase.
DC25 rated @ 20-400 lbs. Force, DC50 rated @ 250-1000 lbs. Force
Mini-H Thermal Press
The Mini-H Series (Model MH1650) is a cost-effective solution for smaller applications, while not sacrificing any structural features vs. the larger and more advanced H-Series Thermal Press. A robust “H-Frame” design can maintain planarity between the thermal tooling and the part holding fixturing, even in forces up to 1000 pounds! Just like all of our Thermal Press systems, it is fully self-contained and can easily sit on most work benches or tables.
1 Year Warranty.
Specifications: 120VAC (15AMP Max) or 240VAC (30 AMP MAX), 50/60Hz, Single-phase.
Custom Thermal Press Systems & Solutions
Larger format equipment including; Film and Filter Conversion Systems, Rotary Indexers (48″- 96″ diameter) and complex multiple actuation systems that are designed and installed to be complete turnkey assembly solutions.
1 Year Warranty.
Specifications: 120VAC, 240VAC, or 480VAC, as required.
*Force and actuation ratings are application and tooling specific
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