U.S. patent application number 11/685692 was filed with the patent office on 2007-07-19 for dielectric welding methods.
This patent application is currently assigned to COOLHEAD TECHNOLOGIES, INC.. Invention is credited to Christopher Lawrence CLARKE, R. David FLETCHER.
Application Number | 20070164018 11/685692 |
Document ID | / |
Family ID | 35308423 |
Filed Date | 2007-07-19 |
United States Patent
Application |
20070164018 |
Kind Code |
A1 |
FLETCHER; R. David ; et
al. |
July 19, 2007 |
DIELECTRIC WELDING METHODS
Abstract
Dielectric welding apparatus has opposed electrodes that can be
engaged on either side of a product to be welded and a dielectric
welding power supply that supplies welding potentials to the
electrodes. The apparatus includes electrically insulating buffer
material adjacent to at least one of the electrodes. A recess
formed in a surface of the buffer material receives an end of an
electrically-conductive member in the product. The buffer material
prevents arcing between the electrodes and the
electrically-conductive member.
Inventors: |
FLETCHER; R. David; (Surrey,
BC) ; CLARKE; Christopher Lawrence; (Langley,
BC) |
Correspondence
Address: |
OYEN, WIGGS, GREEN & MUTALA LLP;480 - THE STATION
601 WEST CORDOVA STREET
VANCOUVER
BC
V6B 1G1
CA
|
Assignee: |
COOLHEAD TECHNOLOGIES, INC.
8014 Webster Road
Delta
CA
V4G 1G6
|
Family ID: |
35308423 |
Appl. No.: |
11/685692 |
Filed: |
March 13, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11128277 |
May 13, 2005 |
7208711 |
|
|
11685692 |
Mar 13, 2007 |
|
|
|
60570817 |
May 14, 2004 |
|
|
|
Current U.S.
Class: |
219/770 |
Current CPC
Class: |
B29C 66/8122 20130101;
B29C 66/8122 20130101; B29C 66/81423 20130101; B29C 66/8322
20130101; B29K 2305/00 20130101; B29C 66/81263 20130101; B29K
2995/0005 20130101; B29C 66/8122 20130101; B23K 11/08 20130101;
B29C 66/81871 20130101; B29C 66/8122 20130101; B29C 66/8122
20130101; B29K 2075/00 20130101; B29K 2823/12 20130101; B29K
2883/00 20130101; B29K 2909/02 20130101; B29K 2027/06 20130101;
B29K 2827/18 20130101; B29K 2075/00 20130101; B29K 2823/06
20130101; B29K 2023/083 20130101; B29C 66/81433 20130101; B29C
66/80 20130101; B29K 2023/083 20130101; B29C 66/45 20130101; B29C
66/8122 20130101; B29C 66/71 20130101; B29K 2027/06 20130101; B29C
66/71 20130101; B29C 66/71 20130101; B29C 66/71 20130101; B29C
66/81431 20130101; B23K 2101/18 20180801; B29C 66/8242 20130101;
B23K 11/002 20130101; B29C 65/04 20130101 |
Class at
Publication: |
219/770 |
International
Class: |
H05B 6/62 20060101
H05B006/62 |
Claims
1. A method for dielectric welding of a product comprising first
and second layers and an electrically-conductive member attached to
at least the first layer, the method comprising: providing a first
electrode; placing the first layer adjacent to the first electrode
with the electrically-conductive member projecting into a recess in
a buffer material adjacent to the first electrode and the second
layer adjacent to the first layer on its side away from the first
electrode; compressing the first and second layers between the
first electrode and a second electrode complementary to the first
electrode; applying a high frequency welding potential between the
first and second electrodes for a time sufficient to cause the
first and second layers to fuse in their portions between the first
and second electrodes.
2. A method according to claim 1 wherein at least one of the
electrodes is in an electrode assembly having a recessed portion
that is recessed away from the other one of the electrodes and the
method comprises urging one of the layers of the product into the
at least one recessed portion.
3. A method according to claim 2 wherein urging the layer of the
product into the at least one recessed portion comprises applying
suction to the recessed portion.
4. A method according to claim 1 comprising fusing the first and
second layers along one or more linear lines of welding.
5. A method according to claim 1 wherein the
electrically-conductive member is one of a plurality of
electrically-conductive members and the method compresses receiving
each of the plurality of electrically-conductive members in a
corresponding recess in the buffer material.
6. A method according to claim 5 wherein the
electrically-conducting members are arranged in an array and the
corresponding recesses are arranged in a corresponding array.
7. A method according to claim 6 comprising fusing the first and
second layers along a seam extending around the array of
electrically-conducting members.
8. A method according to claim 1 comprising fusing the first and
second layers along a seam extending around the
electrically-conducting member.
9. A method according to claim 1 comprising, after applying the
welding potential, waiting for a cooling interval and then
separating the first and second electrodes.
10. A method according to claim 1 comprising fusing the first and
second layers at one or more isolated spots.
11. A method according to claim 10 comprising fusing the first and
second layers along a peripheral seam extending around the
electrically-conductive member and the one or more isolated
spots.
12. A method according to claim 1 wherein the
electrically-conductive member is one of a plurality of
electrically-conductive members of the product and the method
compresses seating each of the plurality of electrically-conductive
members in a corresponding recess in the buffer material before
compressing the first and second layers.
13. A method according to claim 1 comprising urging one of the
first and second layers into a groove in the buffer material to
provide a passage in the product.
14. A method according to claim 13 wherein one end of the
electrically-conductive member is in the passage.
15. A method according to claim 13 wherein urging the one of the
first and second layers into the groove comprises applying suction
to the groove.
16. A method according to claim 1 wherein the
electrically-conductive member penetrates one of the first and
second layers.
17. A method according to claim 16 wherein one end of the
electrically-conductive member is between the first and second
layers during compressing the first and second layers.
18. A method according to claim 1 wherein the
electrically-conductive member projects into both the recess in the
buffer material adjacent to the first electrode and another recess
in a buffer material adjacent to the second electrode.
19. A method for dielectric welding of a product comprising a
plurality of layers of a dielectric material and an
electrically-conductive member passing through at least one layer
of the plurality of layers, the method comprising: placing the
plurality of layers between first and second electrodes with the
electrically-conductive member projecting into a recess in an
electrically non-conducting buffer material adjacent to one of the
first and second electrodes; compressing the plurality of layers
between the first and second electrodes; and, applying a high
frequency welding potential between the first and second electrodes
for a time sufficient to cause the plurality of layers to fuse in
their portions between the first and second electrodes.
20. A method according to claim 19 wherein at least one of the
electrodes is in an electrode assembly having a recessed portion
that is recessed away from the other one of the electrodes and the
method comprises urging one of the plurality of layers into the at
least one recessed portion.
Description
TECHNICAL FIELD
[0001] This application is a divisional of U.S. patent application
Ser. No. 11/128,277 filed on 13 May 2005 and entitled DIELECTRIC
WELDING METHODS AND APPARATUS which claims the benefit under 35
U.S.C. .sctn.119 of U.S. provisional patent application No.
60/570,817 filed on 14 May 2004 and entitled DIELECTRIC WELDING
METHODS AND APPARATUS which is hereby incorporated by reference
herein.
TECHNICAL FIELD
[0002] The invention relates to methods and apparatus for welding
dielectric materials such as plastics. Some embodiments of the
invention relate to welding using electromagnetic signals (e.g.
radiofrequency signals). The invention may be applied to welding
plastic membranes together in the presence of metals or other
exposed electrically conductive materials (hereinafter referred to
as ECM). The invention has broad application for manufacturing
products which include welded plastic membranes that have ECM near
to the weld locations.
BACKGROUND
[0003] Dielectric welding, also known as capacitance,
radio-frequency, or high frequency welding, provides a way to fuse
materials together. The resulting weld can be as strong as the
original workpiece materials. Dielectric welding is commonly used
for joining various plastic materials together.
[0004] In dielectric welding, an alternating electrical field
(typically alternating at a high frequency) is applied across an
area to be welded. This is typically done by applying a signal
between electrodes. The signal creates a varying, high-frequency
electromagnetic field. When a material which is a poor electrical
conductor is exposed to such a field, heat is generated in the
material. The heat results from electrical losses that occur in the
material. The heat deposited in the material causes the temperature
of the material to rise. The heated materials become fused
together.
[0005] Dielectric welding relies on certain properties of the
material in the parts being welded, for example, the geometry and
dipole moments of molecules of the material, to cause the
generation of heat in a rapidly alternating electromagnetic field.
Not all materials can be dielectric welded. Polyvinyl chloride
(PVC) is commonly welded by dielectric welding. Other
thermoplastics that can be dielectric welded are EVA and
polyurethanes.
[0006] A typical dielectric welding apparatus places materials to
be joined between two electrodes, which are typically metal plates
or bars. The electrodes are connected to an oscillator. The
oscillator is turned on to heat the materials, which fuse together
when they have been heated sufficiently. The electrodes may hold
the materials together during heating and cooling.
[0007] There are situations where it is desirable to make products
which have ECM, e.g. metal components, embedded in or attached to
one or more membranes or other parts of a dielectric material which
are to be welded together. A problem is that ECM in the vicinity of
the electrodes of a dielectric welder can cause electrical
discharges in the form of arcs or sparks. Such electrical
discharges can damage the product being made, the welding apparatus
and/or the dielectric welder itself. Electrical arcing can be
dangerous to machines and humans.
[0008] It is not always possible or convenient to add ECM after
welding has been completed. There is a need for methods and
apparatus which may be used to perform dielectric welding in the
vicinity of ECM.
SUMMARY OF THE INVENTION
[0009] The invention relates to methods and apparatus for welding
plastic materials membranes together in the vicinity of
electrically conductive materials.
[0010] Various aspects of the invention and features of specific
embodiments of the invention are described below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] In drawings which illustrate non-limiting embodiments of the
invention,
[0012] FIG. 1 is a schematic view of a dielectric welding
apparatus;
[0013] FIG. 2 is an isometric view showing first and second
electrode assemblies;
[0014] FIG. 3 is a perspective view of one of the electrode
assemblies of FIG. 2;
[0015] FIG. 4 is a plan view of one of the electrode assemblies of
FIG. 2;
[0016] FIG. 4A is a cross sectional view (in the plane A-A of FIG.
4) of the electrode assembly of FIG. 4;
[0017] FIG. 4B is an exploded view of the electrode assembly of
FIG. 4;
[0018] FIG. 5 is a plan view of the other one of the electrode
assemblies of FIG. 2;
[0019] FIG. 6 is an isometric view of a buffer member; FIG. 6A is a
top plan view thereof; FIG. 6B is a section in the plane A-A
thereof; and FIG. 6C is a section in the plane B-B thereof;
[0020] FIG. 7 is an isometric view of a part of an electrode
assembly;
[0021] FIG. 7A is a top plan view thereof; FIG. 7B is a section in
the plane C-C thereof; and FIG. 7C is a section in the plane D-D
thereof;
[0022] FIG. 8 is an isometric view the electrode assembly of FIG. 7
holding a product to be welded with a top membrane removed for
clarity; FIG. 8A is a top plan view thereof; FIG. 8B is a section
in the plane E-E thereof; and FIG. 8C is a section in the plane F-F
thereof;
[0023] FIG. 9 is an isometric view the electrode assembly of FIG. 8
with the top membrane of the product in place to be welded; FIG. 9A
is a top plan view thereof; FIG. 9B is a section in the plane G-G
thereof; and FIG. 9C is a section in the plane H-H thereof;
[0024] FIG. 10 is an isometric view the electrode assembly of FIG.
9 showing electrodes, but not a buffer portion, of a top electrode
assembly; FIG. 10A is a top plan view thereof; FIG. 10B is a
section in the plane I-I thereof; and FIG. 10C is a section in the
plane J-J thereof;
[0025] FIG. 11 is an isometric view the electrode assembly of FIG.
10 showing the buffer portion of the top electrode assembly; FIG.
11A is a top plan view thereof; FIG. 11B is a section in the plane
K-K thereof; and FIG. 11C is a section in the plane L-L
thereof;
[0026] FIG. 12 is an isometric view of the top electrode assembly
portion shown in FIG. 11; FIG. 12A is a top plan view thereof; FIG.
12B is a section in the plane M-M thereof; and FIG. 12C is a
section in the plane N-N thereof; and,
[0027] FIG. 13 is an isometric view of the top electrode assembly
portion shown in FIG. 11 supporting a top membrane of a product;
FIG. 13A is a top plan view thereof; FIG. 13B is a section in the
plane O-O thereof; and FIG. 13C is a section in the plane P-P
thereof.
DESCRIPTION
[0028] Throughout the following description, specific details are
set forth in order to provide a more thorough understanding of the
invention. However, the invention may be practiced without these
particulars. In other instances, well known elements have not been
shown or described in detail to avoid unnecessarily obscuring the
invention. Accordingly, the specification and drawings are to be
regarded in an illustrative, rather than a restrictive, sense.
[0029] Consider the case where one wishes to create a pattern of
welds joining a pair of membranes. The membranes are made of a
plastic material which is suitable for dielectric welding. However,
one or both of the membranes has attached to it, or embedded in it,
one or more electrically conductive elements (ECM). The ECM may,
for example, be metal parts. The ECM may be exposed. If the one or
more ECM is near to a location in which it is desired to weld the
membranes together then the presence of the one or more ECM may
interfere with dielectric welding of the membranes together using
conventional methods.
[0030] Welding methods and apparatus can interpose an electrically
insulating barrier between ECM in a product being fabricated and
the electrodes of a dielectric welder. Provision of an electrically
insulating barrier supports welding non-conductive membranes in
close proximity to ECMs.
[0031] Electrode structures for dielectric welding may have
integrated insulating barriers located so that the insulating
barriers will be interposed between electrodes of the electrode
structures and the ECMs when the electrodes are in position to make
a weld. In some embodiments, the electrode structures include one
or more electrodes arranged in a pattern corresponding to a desired
weld pattern.
[0032] The electrodes may be made of any suitable electrically
conducting materials. Aluminum, brass, and copper are examples of
materials from which electrodes may be fabricated. The electrodes
may be fabricated using any suitable process. For example, the
electrodes may be machined, assembled from component parts, cast,
etc.
[0033] Buffers are located between the electrodes. The buffers are
made of electrically insulating materials. The buffers are hollowed
out to receive projecting portions of one or more ECMs. In some
embodiments the buffers fill the spaces between the electrodes.
[0034] The buffers may be made from any of a wide variety of
suitable materials. Examples of materials suitable for use as
buffers include: electrically non-conductive ceramic materials,
polytetrafluoroethylene, polyurethane, polypropylene, polyethylene,
silicone, and combinations of these materials. The buffers may be
made using any suitable manufacturing processes. For example, the
buffers may be machined or otherwise formed from solid materials or
cast. A castable polyurethane or silicone may be used to cast all
or part of the buffers. The buffers may be partially cast and
partially made from solid materials. In preferred embodiments, the
buffers have dielectric strengths at least 2 times greater than a
dielectric strength of air in a range of frequencies of a high
frequency welding current to be used.
[0035] FIG. 1 shows schematically a dielectric welding apparatus 10
according to one embodiment of the invention. Apparatus 10 includes
first and second electrode assemblies 12A and 12B. Electrode
assemblies 12A and 12B are disposed on either side of a product 14
comprising plastic materials, typically membranes 16, to be welded
together and one or more ECMs 18. First and second electrode
assemblies 12A and 12B each have a face 13 facing toward the other
electrode assembly.
[0036] Apparatus 10 comprises a frame 11. First electrode assembly
12A is supported by frame 11 and is movable toward and away from
second electrode assembly 12B to permit product 14 to be compressed
between electrode assemblies 12A and 12B. In some embodiments,
electrode assemblies 12A and 12B can be pressed together with a
desired force by a mechanical linkage mechanism, a pneumatic or
hydraulic mechanism, an electrically controlled actuator or some
other suitable pressing means. Electrode assemblies 12A and 12B may
be supported by any suitable mechanisms which maintain registration
between electrode assemblies 12A and 12B.
[0037] In the illustrated embodiment, frame 11 may be the frame of
a conventional dielectric welding machine, for example. First
electrode assembly 12A is mounted to a first platen 19A. Second
electrode assembly 12B is mounted to a second platen 19B. Either or
both of the platens are movable to achieve placement of products to
be welded and removal of welded products. Apparatus 10 supports the
compression, welding, and cool down phases of dielectric welding.
As the basic operation and constructions of dielectric welding
machines are understood by those skilled in the art, features known
from conventional dielectric welding apparatus are not described in
detail herein.
[0038] First and second electrode assemblies are each connected to
a dielectric welding power supply 20. In the illustrated
embodiment, the first and second electrode assemblies are in
electrical contact with power supply 20 by way of electrical
contact between their bases (or non-welding sides) and the
corresponding platens 19A, 19B. Except as indicated herein,
apparatus 10 may be constructed and operated in substantially the
same manner as an existing dielectric welding machine. In
operation: [0039] product 14 is compressed between first and second
electrode assemblies 12A and 12B; [0040] power supply 20 is
operated to supply high frequency dielectric welding current to
first and second electrode assemblies 12A and 12B; and, [0041]
after sheets 16 have had an opportunity to fuse together at the
weld locations, the high frequency current is discontinued and,
optionally after a cooling interval, first and second electrode
assemblies are separated to allow the welded product 14 to be
removed.
[0042] FIG. 2 is an isometric view showing first and second
electrode assemblies 12A and 12B according to an example embodiment
of the invention. Each electrode assembly 12A and 12B has one or
more electrodes 30. Electrodes 30 of first electrode assembly 12A
are arranged as a mirror image of electrodes 30 of second electrode
assembly 12B. When first and second electrode assemblies 12A and
12B are brought together face-to-face the electrodes 30 of
electrode assemblies 12A and 12B follow one another. Electrodes 30
of first and second electrode assemblies 12A and 12B are directly
opposed to one another on either side of product 14. The pattern of
electrodes 30 defines the pattern of locations at which membranes
16 will be welded together.
[0043] In the illustrated embodiment, electrodes 30 include a
peripheral electrode 30A which welds a peripheral seam on product
14, internal electrodes 30B which define a pattern of welds in the
interiors of products 14, and electrodes 30C which make spot welds
on product 14. In the illustrated embodiment, electrodes 30A and
30B are linear electrodes and electrodes 30C are isolated spots.
All of the electrodes are electrically connected to an electrically
conducting base 33. When first and second electrode assemblies 12A
or 12B are mounted to corresponding platens 19A and 19B, bases 33
are in electrical contact with the platens and thereby establish
electrical contact between the welding power source 20, which is
connected to the platens, and electrodes 30.
[0044] The spaces between electrodes 30 are filled with buffer
areas 32. In the illustrated embodiment, buffer areas 32 are
composed of a cast material 32 cast between electrodes 30.
[0045] Buffer areas 32 have recesses 34 to receive the projecting
parts of ECMs 18. Recesses 34 may be shaped to substantially
conform with the shapes of the projecting parts of ECMs 18.
Different ones of recesses 34 may have different shapes and
configurations.
[0046] As shown best in FIG. 4A, buffers 32 fill the space between
electrodes 30. Buffers 32 are flush with the tops of electrodes 30.
Buffers 32 provide barriers 33 of electrically insulating material
between recesses 34 and electrodes 30.
[0047] When first and second electrode assemblies are brought
together on either side of product 14, the embedded and projecting
ECMs 18 are seated in features 34. This insulates ECMs 18 from
electrodes 30. Features 34 can also support, locate, and align ECMs
18 in relation to one another and the membranes 16 to be
welded.
[0048] Buffer areas 32 may optionally contain features to pre-form,
locate and pre-align membranes 16 to be welded. Such features may
include electrical-mechanical devices and or intermittent
differential air pressures or vacuums.
[0049] Buffer areas 32 may contain features to assist the ejection
and removal of welded membranes with embedded ECM from the major
components of the device. Such features could be implemented, for
example, by providing electrical-mechanical devices and or
intermittent differential air pressures or vacuums.
[0050] FIGS. 6 through 13C are more detailed views of portions of
example first and second electrode assemblies which cooperate to
make a weld.
[0051] FIG. 6 shows a section of buffer material 32 which extends
between a pair of electrodes 30 in an electrode assembly 12B as
shown in FIG. 7. FIG. 7 shows only a part of electrode assembly
12B. Electrode assembly 12B cooperates with another electrode
assembly 12A as shown in FIG. 11. When electrode assemblies 12A and
12B are brought together on either side of a product 14, electrodes
30 of electrode assembly 12A overlie and are aligned with
electrodes 30 of electrode assembly 12B.
[0052] As shown in FIGS. 8 through 11C, an ECM 18 is received in
recess 34 of electrode assembly 12B. ECM 18 is attached to a first
membrane 16B of a weldable plastic material. Recess 34 is shaped to
generally correspond to the shape of the end of ECM 18 which
projects from membrane 16B on the side toward electrode assembly
12B.
[0053] As shown in FIGS. 9 through 11C, a second membrane 16A of
product 14 is curved away from membrane 16B to provide a tubular
passage 37 in product 14. The buffer 32 of first electrode assembly
12A is cut away to form a groove 38 which accommodates and shapes
second membrane 16A. Vacuum ports (not shown) may be provided in
buffer 32 of second electrode assembly 12A to pull second membrane
16A into and against the contours of groove 38 prior to welding.
After welding, the end of ECM 18 which is closest to first
electrode assembly 12A is located within passage 37.
[0054] Applying a high frequency alternating welding current
between electrodes 30 of first electrode assembly 12A and second
electrode assembly 12B causes membranes 16B and 16A to become fused
together at locations 17 (FIG. 11B).
[0055] Where a component (e.g. a member, part, assembly, device,
circuit, etc.) is referred to above, unless otherwise indicated,
reference to that component (including a reference to a "means")
should be interpreted as including as equivalents of that component
any component which performs the function of the described
component (i.e., that is functionally equivalent), including
components which are not structurally equivalent to the disclosed
structure which performs the function in the illustrated exemplary
embodiments of the invention.
[0056] As will be apparent to those skilled in the art in the light
of the foregoing disclosure, many alterations and modifications are
possible in the practice of this invention without departing from
the spirit or scope thereof. For example: [0057] Buffers 32 are not
necessarily present in areas away from ECMs. [0058] Buffers 32 are
present in only one of first and second electrode assemblies in
some embodiments of the invention. [0059] The widths of electrodes
30 may be varied. [0060] Electrodes 30 may be arranged to form any
suitable pattern. [0061] A welding power supply may be connected
directly to electrodes 30 or bases 33 instead of indirectly by way
of platens 19A and 19B, as illustrated.
[0062] While a number of example aspects and embodiments have been
discussed above, those of skill in the art will recognize certain
modifications, permutations, additions and sub-combinations
thereof. It is therefore intended that the following appended
claims and claims hereafter introduced are interpreted to include
all such modifications, permutations, additions and
sub-combinations as are within their true scope.
* * * * *