CN101765626A - 用于采用导电性和磁性颗粒进行感应控制加热的温控聚合物组合物 - Google Patents

用于采用导电性和磁性颗粒进行感应控制加热的温控聚合物组合物 Download PDF

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CN101765626A
CN101765626A CN200880021956A CN200880021956A CN101765626A CN 101765626 A CN101765626 A CN 101765626A CN 200880021956 A CN200880021956 A CN 200880021956A CN 200880021956 A CN200880021956 A CN 200880021956A CN 101765626 A CN101765626 A CN 101765626A
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particle
magnetic
polymer composition
composition
polymer
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德鲁·P·拉马尔卡
布赖恩·阿戈斯托
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/20—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder
    • H01F1/22—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together
    • H01F1/24—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
    • H01F1/26—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated by macromolecular organic substances
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    • B29C65/3608—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the type of elements heated by induction which remain in the joint comprising single particles, e.g. fillers or discontinuous fibre-reinforcements
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    • B29C66/9161—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux
    • B29C66/91651—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux by controlling or regulating the heat generated by Joule heating or induction heating
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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Abstract

一种聚合物组合物，其具有聚合物基体材料和磁性颗粒。所述组合物可通过电感能量频率进行选择性电磁加热，所述频率通过可变时间周期进行脉冲宽度调制，以提供可控制的加热。

Description

用于采用导电性和磁性颗粒进行感应控制加热的温控聚合物组合物
本申请要求2007年6月26日提交的临时申请60/937,401的优先权，其内容以引用方式并入本发明。
背景技术
本发明涉及聚合物感应粘接。这种粘接被用于封装、焊接、铸造或固化聚合物材料。
目前，用于这种粘接的材料是由如下方法制备的：将塑性聚合物与磁性颗粒复合，并通过被设定为Khz-Mhz的单频电感频率加热。所述材料以粒料和固体型材材料的形式制成。在应用焊接材料时，由于几何形状和进入所应用的特定装置，因而存在局限性。粒料和型材的尺寸也限制了其应用于装置中。
已知有各种用于感应粘接的材料。例如，美国专利No.6,048,599公开了用于电磁熔融粘接的片状材料，其包括许多复合的电磁部分，所述电磁部分包括邻近聚合物部分均匀分散的感受器颗粒。所述复合部分与每个相邻的聚合物部分粘接，使得复合部分和聚合物部分形成交替部分的图案排列。
美国专利No.6,056,844公开了通过将铁磁体颗粒混合在待加热的聚合物中，对聚合物材料进行温控感应加热。温度控制是通过选择具有特定居里温度(Tc)的铁磁体颗粒获得的。所述铁磁体颗粒在感应场中，通过磁滞损耗加热，直至它们达到它们的居里温度(Tc)。在该点上，停止通过磁滞损耗产生热。
美国专利No.6,939,477公开了聚合物材料的温控感应加热，其中，将能产生磁场的感应线圈置于所述材料的附近，并加热待加热的材料中的感受器如金属网或粉末。为了改善感应加热工艺，对感受器的设计进行了优化从而能有效地熔融粘接或焊接热塑性层，对将感受器颗粒混入或置于复合材料基体中的方法进行了优化，并且对感应设备的功率频率(power infrequency)进行了优化。
美国专利No.5,643,390公开了用于高性能热塑性组合物的粘接技术，其中选择热塑性材料和热固性单体，使得所述热固性单体具有与所述热塑性材料类似的溶度参数。所述热塑性材料被直接粘接到所述热固性单体的表面，从而得到共固化(co-cured)的层状材料，所述粘接用热固性粘结剂粘接或者是通过熔融而进行。
美国专利No.6,137,093公开了高效加热试剂，其是由用于交变磁场的铁磁体纤维组成的。
这些现有技术的感应加热技术，以及其他公知的技术，能提供非常快的加热和粘接速率，但是对于粘接线温度(bond-linetemperature)的控制很差。
发明简述
本发明的一个目的是改进现有技术，并提供一种能在作为粘接材料使用的过程中，通过脉冲宽度调制(PWM)进行控制的组合物。
本发明提供了一种新的聚合物感应粘接技术。感应加热技术被用于封装、焊接、铸造、粘接或固化聚合物材料，所述感应加热技术采用了从电能感应源所获得的固定的持续时间(ON/OFF)。本发明提供了通过电感能量的可变时间，对聚合物基体材料进行温控感应加热，所述电感能量的可变时间是采用脉冲宽度调制(PWM)的可变时间周期实现的。
采用可变感应磁场对聚合物基体加热进行的控制，来自由所述聚合物基体中的导电性或磁性材料所产生的热量。这些感应材料是混合在聚合物相容性基体中的，其可具有从液体到固体的稠度(consistency)，并能对所述感应能量脉冲宽度调制做出反应。这些频率依赖性颗粒在该感应场中，会加热至特定的温度或沿特定温度曲线加热，这取决于所传递的感应能量。
通过磁滞损耗产生的感应热停止，所述磁滞损耗来自铁磁性材料或者非磁性或导电性材料的涡流(趋肤效应)。本发明可借助感应性聚合物基体以及电感能量的时间周期脉冲，用于粘接热塑性材料或者热固性组合物，和固化热固性胶粘剂，以及采用复合树脂或者聚合物进行封装。
本发明能采用新的、与所应用的特定装置相适应的液体、凝胶、粉末或者固体类型的材料。
所述新材料的新颖之处在于，其以纳米尺寸结构至微米尺寸的感应材料为起始，所述感应材料涂覆有特定的聚合物并复合到聚合物基体粒料中。所述复合的粒料以多种方式使用，如下文所述。
液体和凝胶——复合的聚合物基体粒料被加工成尺寸为大于或等于1微米的粉末。液体和凝胶基于电磁粘接粉末和粘性表面张力促进剂的组合物，以形成柔韧的聚合物基体，所述基体可用于封装、固化、粘接和焊接，这取决于所述液体和凝胶的分散方法。
粉末——复合的聚合物基体粒料被加工成尺寸为大于或等于1微米的粉末。所述粉末采用粉末分散器、热分散或者喷雾施加。
粒料——作为用于特定加工工艺的聚合物基体粒料。
型材——聚合物基体粒料被复合成固体形态。
聚合物结构——聚合物基体粒料可采用聚合物加工设备或者技术，与其他聚合物和用于特定加热的感应性材料(例如，薄膜或片材)一起，进行加工。
这种电磁精确加热的新颖之处在于可变感应时间，其采用处于固定的Khz-Mhz的单频电感能量频率，所述频率通过可变时间周期进行脉冲宽度调制，这就产生了精确的电磁加热方法。通过由导电性或磁性颗粒随着时间的推移而吸收的总能量，对电能转化为感应热进行控制。
电磁场与聚合物基体中的感受器颗粒的相互作用，产生了可控制的靶向加热。
本发明的方法能在塑性焊接材料的一个或多个立体层内产生均匀的热量。这降低了副作用，如热降解和热引发的残余应力，同时相对于紧凑的剪切接口设计、速度和能量效率而言，又提供了多个优点。
由本发明下文的描述，本发明的其他特征和优点变得显而易见。
附图简介
图1是示意图，其显示了用于实施粘接的系统的设备，所述粘接采用本发明的聚合物组合物；
图2是图表，其显示了采用本发明的组合物的加热速率的例子；以及
图3是图表，其显示了加热效率。
发明详述
下文将描述用于感应控制加热的、本发明的温控聚合物组合物的应用，所述感应控制加热采用导电性和磁性颗粒。
高频匹配阻抗调谐器1和发生器2，所述发生器2接受由控制信号产生的所期望的感应热响应指令，所述控制信号由用于获得所期望的感应能量响应的微控制器3产生。每个控制信号具有所期望的时间频率和所期望的占空比。高频功率回路接受控制信号4，并产生作为响应的固定的或可变的频率脉冲宽度调制信号。每个频率脉冲宽度调制的信号具有对应于所期望的磁热效应的至少两个固定频率中的一个，并且具有对应于所期望的占空比的多个活动占空比(activeduty cycle)中的一个，从而获得一定水平的感应功率以控制导电性和磁性颗粒的加热。所述占空比可为0-100％。
磁场工作线圈5从所述高频功率发生器线圈接受固定的或者可变的频率脉冲宽度调制的信号，以控制工作线圈5的磁通密度。
所述高频功率发生器线圈在80KHz-30MHz下工作。
本发明的用于控制感应加热温度的聚合物组合物包括：至少一种聚合物基体材料，以及磁性或导电性颗粒，其中所述颗粒的尺寸为大于或等于约10纳米。
在所述聚合物组合物的一个具体实施方案中，所述导电性和磁性颗粒均匀地分散在所述聚合物基体材料中。
在所述聚合物组合物的另一个具体实施方案中，所述聚合物基体材料具有大于或等于约1微米的尺寸，以制备固体型材。
所述聚合物组合物可具有约1wt％-约75wt％或更高的导电性和磁性颗粒，这取决于基体聚合物反应。
在所述聚合物组合物的又一个具体实施方案中，所述聚合物基体材料包括热塑性材料。
所述热塑性材料可为聚(醚醚酮)、聚醚酮酮、聚(醚酰亚胺)、聚苯硫醚、聚砜、聚对苯二甲酸乙二醇酯、聚酯、聚酰胺、聚丙烯、聚氨酯、聚苯醚、聚碳酸酯、聚丙烯/聚酰胺、聚丙烯/乙烯乙烯醇、聚乙烯、聚烯烃低聚物、液体改性的聚烯烃或它们的组合。
在所述聚合物组合物的又一个具体实施方案中，所述导电性和磁性颗粒的居里温度(Tc)大于所述聚合物基体材料的熔点。
所述聚合物组合物还可包括粘性聚合物基体材料，所述基体材料可包括溶剂或醇溶液，水分散体、微米尺寸的聚合物基体颗粒和氧化的涂料。
对于所述热固性组合物而言，还能具有粘性热固性基体材料，所述基体材料包括热固性胶粘剂或者封装和微米尺寸的聚合物基体颗粒。
此外，所述微米尺寸的聚合物基体颗粒的居里温度(Tc)为大于所述热固性组合物材料的固化温度。
本质上，通过改变脉冲宽度调制(PWM)，对聚合物基体组合物中的导电性颗粒进行控制，由此可对所述组合物和磁性颗粒的加热进行精确控制。
图2示意了在脉冲宽度调制(PWM)过程中的加热速率。由该图表可以看出，当脉冲宽度调制(PWM)的百分比从0-30％增加时，所述聚合物基体的温度稍有上升。当脉冲宽度调制的百分比增大至80％时，所述聚合物基体/组合物的温度均匀上升。然后，当脉冲宽度调制的百分比增大至100％时，所述基体/组合物的温度有更显著的增大。当脉冲宽度调制的百分比再一次下降时，可以看到在相反方向也出现类似的趋势。
图3给出了一个实施例，其中所期望的加热效果通过采用脉冲宽度调制进行控制。如图所示，起初脉冲宽度调制的百分比逐渐上升，伴随着温度的逐渐上升。随后，当脉冲宽度调制升至50％时，所述温度有一个更明显的上升，在该例子中，约为250°。通过将脉冲宽度调制保持在50％而保持所述温度。一旦完成粘接和焊接，就不再需要加热了，再次降低脉冲宽度调制的百分比，其伴随着温度的下降。
上述实施例仅仅代表了用于加热聚合物基体以进行粘接的控制的类型。当然，脉冲宽度调制的百分比和温度会随着不同的应用而变化，这取决于聚合物基体组合物中所用的材料，以及待粘接的或熔接的组分。
尽管本发明已经对与特定的具体实施方案相关的内容进行了描述，许多其他变化和改变以及其他应用，对于本领域技术人员而言是显而易见的。因此，优选地，本发明不受这些所公开的具体内容的限制，而是仅仅由所附的权利要求书所限制。

Claims (20)

1.聚合物组合物，包括：
聚合物基体材料和磁性颗粒，由此所述组合物可通过电感能量频率选择性电磁加热，所述频率通过可变时间周期进行脉冲宽度调制。
2.如权利要求1所述的聚合物组合物，进一步包括导电性颗粒。
3.如权利要求2所述的聚合物组合物，其中，所述颗粒的尺寸为大于或等于约10纳米。
4.如权利要求2所述的聚合物组合物，其中，所述导电性和磁性颗粒均匀地分散在聚合物基体材料中。
5.如权利要求1所述的聚合物组合物，其中，所述聚合物基体材料包括尺寸大于或等于约1微米的聚合物基体颗粒。
6.如权利要求2所述的聚合物组合物，其中，所述导电性和磁性颗粒以约1wt％-约75wt％的量存在。
7.如权利要求1所述的聚合物组合物，其中，所述聚合物基体材料是热塑性材料。
8.如权利要求7所述的聚合物组合物，其中，所述热塑性材料选自如下物质的组：聚(醚醚酮)、聚醚酮酮、聚(醚酰亚胺)、聚苯硫醚、聚砜、聚对苯二甲酸乙二醇酯、聚酯、聚酰胺、聚丙烯、聚氨酯、聚苯醚、聚碳酸酯、聚丙烯/聚酰胺、聚丙烯/乙烯乙烯醇、聚乙烯、聚烯烃低聚物、液体改性的聚烯烃或它们的组合。
9.如权利要求2所述的聚合物组合物，其中，所述导电性和磁性颗粒具有大于所述聚合物基体材料的熔点的居里温度(Tc)。
10.如权利要求5所述的聚合物组合物，其中，所述聚合物基体材料是粘性的，并且包括溶剂、醇或水分散体、微米尺寸的聚合物基体颗粒和氧化的涂料。
11.热固性组合物，包括：
粘性热固性基体材料，包括热固性粘结剂或者封装和微米尺寸的聚合物基体颗粒；以及
磁性颗粒，由此所述组合物可通过电感能量频率电磁加热，所述频率通过可变时间周期进行脉冲宽度调制。
12.如权利要求11所述的热固性组合物，其中，所述微米尺寸的聚合物基体颗粒具有大于所述热固性基体材料的固化温度的居里温度(Tc)。
13.温控粘接方法，包括如下步骤：
将磁性颗粒分散在聚合物基体材料中，形成聚合物组合物；
采用电感能量频率对所述组合物进行电磁加热；以及
通过可变时间周期对所述频率进行脉冲调制。
14.如权利要求13所述的方法，包括将导电性颗粒分散在聚合物基体材料中。
15.如权利要求14所述的方法，其中，所述频率处于80KHz-30MHz的范围之内。
16.如权利要求14所述的方法，包括将所述导电性和磁性颗粒均匀分散在所述聚合物基体材料中。
17.如权利要求14所述的方法，其中，每个频率脉冲宽度调制的信号都具有对应于所期望的磁热效应的至少两个固定频率中的一个。
18.如权利要求17所述的方法，其中，每个脉冲宽度调制信号都通过对应于所期望的占空比的多个活动占空比中的一个进行调制，从而获得一定水平的感应功率以控制导电性和磁性颗粒的加热，所述占空比为0-100％。
19.用于含有聚合物基体材料以及导电性和磁性颗粒的聚合物组合物的感应控制加热的系统，包括：
高频功率发生器；
连接到所述功率发生器上的高频匹配阻抗调谐器；
连接到所述功率发生器上、用于调制所述发生器的输出功率的脉冲宽度调制器；
用于产生控制信号的控制单元，所述控制信号具有所期望的时间频率和所期望的占空比，所述控制信号被送至所述脉冲宽度调制器和功率发生器中，从而产生固定的或可变的频率脉冲宽度调制信号，所述信号的每一个都具有对应于所期望的磁热效应的至少两个固定的频率中的一个；以及
连接到所述调谐器上的磁场工作线圈，以接受所述固定或可变的频率脉冲宽度调制的信号并且控制所述工作线圈的磁通密度，由此所述工作线圈加热聚合物组合物，所述组合物采用了导电性和磁性颗粒。
20.如权利要求19所述的系统，其中，所述功率发生器、调谐器和脉冲宽度调制器形成在80KHz-30MHz的范围内工作的高频功率发生器回路。
CN200880021956A 2007-06-26 2008-06-25 用于采用导电性和磁性颗粒进行感应控制加热的温控聚合物组合物 Pending CN101765626A (zh)

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