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Thermoplastic welding
| Details |
Inventors: Grimm, Robert A.; Grewell, David A.; St. John, Marc;
Assignee: Edison Welding Institute, Inc. (Columbus, OH)
Primary Examiner: Reynolds; Bruce A.
Assistant Examiner: Hoang; Tu
Attorney, Agent or Firm: Watkins, Dunbar & Pollick
A process for obtaining long, continuous, thermoplastic welds on large structures. A series of tabs are used in pairs and especially in alternating, overlapping pairs to obtain resistance heating of a strip material placed in the bond line. The resistance of the tabs is less than that of the strip material. Conducting braid-tubes afford continuous welding when the bond line is curved. Alternatively, an electromagnetic field is used to take advantage of the induction heating. A wide susceptor is used to weld a current conducting substrate while avoiding bulk heating of the substrate. The unexpected property of current-conducting braid-tube susceptors, in which induction heating takes place at the center rather than at the edges of a flattened braid-tube susceptor, is used to obtain long continuous curved welds. |
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DETAILED DESCRIPTION It is an object of this invention to obtain long, continuous (unbroken), thermoplastic welds on large substrates with a minimal amount of bulk heating of the substrate itself.
One way in which this invention accomplishes this object is by using a series of tabs that are used in pairs and especially in "leap-frog" pairs (alternating and overlapping pairs) to obtain resistance heating preferably using non-metallic conductors.
Another way this object is accomplished by using induction heating taking advantage of the induction heating of woven conductors and the unexpected property of current-conducting braid tubes in which induction heating takes place along the "center" surfaces of a flattened braid tube rather than at the edges as is the case with induction, eddy-current heating of flat, planar conducting materials.
In the resistance heating embodiment of thermoplastic welding, a welding strip is placed in the bond line of the substrate surfaces to be bonded.
The bond line must contain a thermoplastic, that is, a plastic that softens and becomes sufficiently fluid to adhere and fuse to the substrate surfaces which it contacts.
As herein defined and used, the term thermoplastic excludes those materials that are unable to adhere or fuse to the substrate surfaces which it contacts.
The thermoplastic may be an integral part of or attached to 1) one or more of the substrate surfaces to be bonded, 2) the welding strip, 3) otherwise placed in the bond line or 4) various combinations of these arrangements.
The welding strip consists of a continuous, non-metallic, current-conducting strip that extends along the bond line of the surfaces to be bonded.
For the purposes of this invention, the term strip includes all continuous, non-metallic conductors regardless of their shape, form or origin.
Preferably the strip contains a plurality of carbon conductors derived from polymeric fibers such as polyacrylonitrile (PAN) fibers.
Most preferably, such fibers are unidirectional (UD).
To facilitate handling, these fibers are consolidated into a thermoplastic
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Finance 
