CN106455750B - 通过射频焊接制造异形物体的方法及其加工工具总成 - Google Patents

通过射频焊接制造异形物体的方法及其加工工具总成 Download PDF

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Publication number
CN106455750B
CN106455750B CN201580027349.7A CN201580027349A CN106455750B CN 106455750 B CN106455750 B CN 106455750B CN 201580027349 A CN201580027349 A CN 201580027349A CN 106455750 B CN106455750 B CN 106455750B
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special
component
shaping jig
wire mesh
shaped object
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CN106455750A (zh
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布赖恩·克拉夫特
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Nike Innovation LP
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Nike Innovation LP
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    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B13/00—Soles; Sole-and-heel integral units
    • A43B13/14—Soles; Sole-and-heel integral units characterised by the constructive form
    • A43B13/18—Resilient soles
    • A43B13/20—Pneumatic soles filled with a compressible fluid, e.g. air, gas
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B7/00—Footwear with health or hygienic arrangements
    • A43B7/14—Footwear with health or hygienic arrangements with foot-supporting parts
    • A43B7/1405—Footwear with health or hygienic arrangements with foot-supporting parts with pads or holes on one or more locations, or having an anatomical or curved form
    • A43B7/1415—Footwear with health or hygienic arrangements with foot-supporting parts with pads or holes on one or more locations, or having an anatomical or curved form characterised by the location under the foot
    • A43B7/144—Footwear with health or hygienic arrangements with foot-supporting parts with pads or holes on one or more locations, or having an anatomical or curved form characterised by the location under the foot situated under the heel, i.e. the calcaneus bone
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/04—Dielectric heating, e.g. high-frequency welding, i.e. radio frequency welding of plastic materials having dielectric properties, e.g. PVC
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7841—Holding or clamping means for handling purposes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/301—Three-dimensional joints, i.e. the joined area being substantially non-flat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/349—Cooling the welding zone on the welding spot
    • B29C66/3494—Cooling the welding zone on the welding spot while keeping the welding zone under pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/433—Casing-in, i.e. enclosing an element between two sheets by an outlined seam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
    • B29C66/474—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially non-flat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/532—Joining single elements to the wall of tubular articles, hollow articles or bars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • B29C66/7234—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered comprising a barrier layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
    • B29C66/7314—Electrical and dielectric properties
    • B29C66/73143—Dielectric properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/812—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/8124—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the structure of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/812—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/8124—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the structure of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/81241—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the structure of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps being porous or sintered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81411—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat
    • B29C66/81421—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave
    • B29C66/81422—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave being convex
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81411—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat
    • B29C66/81421—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave
    • B29C66/81423—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave being concave
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8145—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81451—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps being adaptable to the surface of the joint
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8145—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81457—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps comprising a block or layer of deformable material, e.g. sponge, foam, rubber
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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Abstract

一种方法，包括在第一成型工具和第二成型工具之间压缩非介电的弹性可变形部件、金属丝网部件和介电异形物体。一经部件被压缩，射频能就被提供给第一成型工具，由此使射频电磁场在第一成型工具和金属丝网部件之间产生，射频电磁场引起异形物体的异形焊缝。一种加工工具总成，配置用于实施该方法。

Description

通过射频焊接制造异形物体的方法及其加工工具总成
技术领域
当前教导总体包括通过射频焊接制造异形物体的方法以及用于实施该方法的加工工具总成。
背景技术
射频焊接是通过在电极之间将部件彼此按压来使介电部件彼此接合的程序。提供射频能量，使电极在将要被接合的部件的表面处产生电磁场。由于部件的一种或多种材料是介电的，所以电磁场激发材料，从其内加热材料并且在如同接合材料一样牢固的无缝结合部或焊缝处将部件的表面彼此熔接。
射频焊接通常在配置用于向将要被接合的部件施加压力的顶部成型工具和底部成型工具之间实施。当部件具有复杂的异形(contoured)外表面时，难以确保加工工具在确保最佳焊缝所需的全部区域内向部件可靠地施加足够的压力。相应地，具有定制模具腔的专用加工工具有时被用于确保加工工具贴合到将要被接合的部件的外表面并且支撑该外表面。可选地，一系列的垫片可以适配在平面加工工具和将要被接合的部件之间，从而更紧密地贴合到部件的异形外表面。这些选择是相对昂贵的并且可能减慢制造时间，因为在加工工具腔内的部件或垫片的特定设置是必要的。
附图说明
图1是用于鞋类物品的气囊元件的示意性透视示图。
图2是金属丝网的示例性透视示图。
图3是非介电弹性可变形部件的示意性透视示图。
图4是用于射频焊接的加工工具总成的横截面分解图的示意性示图，包括图2的金属丝网以及图3的非介电的弹性可变形部件，并且示出了沿图1的线4-4截取的图1的气囊元件。
图5是图4的加工工具总成的示意性横截面的示图，该加工工具总成焊接图1的气囊元件。
图6是使用图4-5的加工工具总成制造图1的气囊元件的方法的流程图。
图7是用于鞋类物品的气囊元件的另一实施例的示意性平面视图。
图8是使用图9-10的加工工具总成来制造图7的气囊元件的方法的流程图。
图9是加工工具总成的可选实施例的横截面分解图的示意性示图，包括金属丝网以及非介电弹性可变形部件，并且示出了沿图7的线9-9截取的图7的气囊元件。
图10是图9的加工工具总成的示意性示图，该加工工具总成焊接图7的气囊元件。
具体实施方式
提供一种通过射频焊接来制造介电的异形物体的方法以及用于射频焊接这种物体的总成。使用相对简单的加工工具部件并且不需要针对特定的异形物体定制加工工具。更具体地，“软的”或“柔性的”加工工具实现了甚至是在具有复杂三维外表面的部件上一致压力的施加以及磁能的产生。相应地，甚至实现了部件的异形焊缝。
该方法包括在第一成型工具和第二成型工具之间压缩非介电(non-dielectric)的弹性可变形部件、金属丝网部件以及介电的异形物体。例如，非介电的弹性可变形部件可以是聚合物泡沫、泡沫橡胶、丁基橡胶或其它合适的材料。在压缩期间，异形物体被定位在第一成型工具和金属丝网部件之间，并且弹性可变形部件位于金属丝网部件和第二成型工具之间。
利用足够的压力实现压缩，以使弹性可变形部件弹性变形并且抵靠异形物体的异形表面按压柔性的金属丝网部件。换言之，在第二成型工具和异形物体之间压缩弹性可变形部件和柔性金属丝网，使弹性可变形部件在一些区域比在其它区域压缩的更多以填充位于第二成型工具和异形物体的外表面之间的不规则空间。柔性金属丝网部件由此偏置为抵靠异形物体的外表面。
一经部件被压缩，则该方法通过向第一成型工具提供射频能量而继续，由此在第一成型工具和金属丝网部件之间产生射频电磁场，该射频电磁场使其产生异形物体的异形焊缝。金属丝网部件和弹性可变形部件有效地用作“软加工工具”以使第二成型工具延伸到异形物体。这使得射频能可以更均匀地施加到异形物体——包括它的异形表面处——以产生所需的焊缝。利用射频焊接，仅在提供射频能时产生热，并且局部化在焊缝处。并非是如利用需要加热加工工具的其它类型的焊接那样加热被焊接的整个物体。
在一个实施例中，异形焊缝是异形物体的第一部分与异形物体的第二部分的焊缝。
在实施例中，该方法包括在第一成型工具和异形物体之间设置第二部件，并且异形焊缝是异形物体与第二部件的焊缝。例如，异形物体可以是用于鞋类物品的气囊元件，并且第二部件可以是用于鞋类物品的鞋面。在这样的实施例中，该方法可以进一步包括在第一成型工具和第二成型工具之间压缩非介电的弹性可变形部件、金属丝网部件和气囊元件之前使气囊元件充气。
在一个实施例中，弹性可变形部件支撑在第二成型工具上，金属丝网部件支撑在弹性可变形部件上，并且该方法包括停止提供射频能以及在停止提供射频能之后的至少预定时间量期间保持弹性可变形部件、金属丝网部件和异形物体的压缩。在这样的实施例中，该方法进一步包括通过将第一成型工具从第二成型工具移除、将第二成型工具从第一成型工具移除或两者都有来释放弹性可变形部件、金属丝网部件和异形物体上的压力，以及将被焊接的异形物体从成型工具之间移除。
在异形物体是用于鞋类物品的气囊元件的实施例中，该方法可以包括使气囊元件充气。异形焊缝可以是气囊元件的外片与气囊元件内的内部织物元件之间的焊缝，并且使气囊元件充气可以发生在将被焊接的异形物体从成型工具之间移除之后。
在实施例中，金属丝网部件是第一金属丝网部件，并且异形焊缝是第一异形焊缝。在第一成型工具和第二成型工具之间压缩非介电的弹性可变形部件、金属丝网部件和气囊元件进一步包括在弹性可变形部件和异形物体之间压缩第二金属丝网部件。第二金属丝网部件与第一金属丝网部件隔开以使提供的射频能使其产生异形部件的第二异形焊缝。
在实施例中，异形物体是具有第一片和第二片的可充气气囊元件。弹性可变形部件变形以通过弹性变形部件分散压力，从而使金属丝网部件弯曲以贴合到异形物体的异形表面。射频电磁场产生气囊元件的至少一个片的异形焊缝。例如，在实施例中，异形焊缝是气囊元件的至少一个片与气囊元件内的内部编织元件的焊缝，并且该方法进一步包含将被焊接的气囊元件从成型工具之间移除以及在从成型工具之间移除被焊接的气囊元件之后使气囊元件充气。
在实施例中，异形焊缝是气囊元件所述至少一个片与鞋类制品的鞋面的焊缝，并且该方法进一步包括在第一成型工具和第二成型工具之间压缩非介电的弹性可变形部件、金属丝网部件和介电的异形物体之前，在第一成型工具和气囊元件之间设置鞋类物品的鞋面并且使气囊元件充气。
用于射频焊接介电的异形物体的总成包括第一成型工具和第二成型工具，至少其中一个配置为可朝向另一个移动以及移动离开另一个。该总成进一步包括支撑在第二成型工具上的非介电的弹性可变形部件以及支撑在非介电的弹性可变形部件上的金属丝网部件。第一成型工具和金属丝网部件配置为向介电的异形物体传输射频能，该介电的异形物体通过如下方式被压缩在第一成型工具和金属丝网部件之间，即，通过使所述至少其中一个成型工具朝向另一个成型工具移动，并且通过弹性可变形部件弹性变形来将成型工具的压力分布在金属丝网部件上。这使得金属丝网部件弯曲并且被按压成抵靠介电的异形物体的异形表面以提供异形物体的异形焊缝。
在各种实施例中，非介电的弹性可变形部件是聚合物泡沫、泡沫橡胶和丁基橡胶中的至少一种，和/或金属丝网部件是青铜、黄铜、铜和不锈钢中的一种或它们的合金，和/或金属丝网部件具有每英寸120乘120的金属线至每英寸500乘500的金属线。
在实施例中，非介电的弹性可变形部件具有支撑金属丝网部件的表面，并且该表面在成型工具之间未被压缩时是大体扁平的。
在实施例中，非介电的弹性可变形部件是柔性的并且金属丝网部件具有柔性，该柔性使金属丝网部件在预定压力下被压缩时能够贴合到异形表面。
在实施例中，金属丝网部件是第一金属丝网部件，异形焊缝是第一异形焊缝并且该总成进一步包含支撑在非介电的弹性可变形部件上的第二金属丝网部件。第二金属丝网部件与第一金属丝网部件以及第一成型工具隔开，并且第二金属丝网部件配置用于向介电的异形物体传输射频能以提供异形物体的第二异形焊缝。
在实施例中，该总成与介电的异形物体结合并且介电的异形物体是具有至少部分热塑性聚氨酯(TPU)片的可充气气囊元件。
在实施例中，该总成与介电的异形物体结合并且进一步与鞋面结合并且异形焊缝位于鞋面和气囊元件之间。
该方法和加工工具总成实现了使用射频焊接来提供异形物体的可靠焊缝的相对不复杂的成型工具。事实上，现有的加工工具总成在添加一个或多个金属丝网部件以及一个或多个非介电的弹性可变形部件的情况下可以适于实施该方法。在一些应用中可以优选地使用射频焊接来代替需要使用粘结剂或溶剂的焊接程序。
“一”、“该”、“至少一个”以及“一个或多个”可以用于可互换地指示存在至少一个该项目；可以存在多个这样的项目，除非上下文另有明确表示。在包括所附权利要求的说明书内的所有参数(例如量或条件)的数值应该理解为在所有示例中通过术语“约”进行修饰，无论数值前面实际出现或未出现术语“约”。“约”表示所述数值容许一定程度的轻微的不精确(一定程度上接近精确的数值；近似或合理地接近该值；差不多)。如果由“约”所提供的不精确性不能在本领域另外理解为该普通的含义，那么这里所用的“约”表示可以由普通测量方法以及使用这样的参数所产生的至少一些变化。此外，公开的范围应理解为特定地公开所有数值以及该范围内进一步细分的范围。
术语“包含”、“包括”以及“具有”是包括性的并且因此说明所述特征、步骤、操作、元件或部件的存在，但并不排除一个或多个其它特征、步骤、操作、元件或部件的存在或添加。在可行时，步骤、程序和操作的顺序可以改变，可以采用另外或可选的步骤。如说明书中所使用的，术语“或”包括相关所列项目的任何一个以及所有组合。
具有本领域普通技术的人员可以明白的是，如“上”、“下”、“向上”、“向下”、“顶部”、“底部”等的术语被用于说明附图，并不表示限制本发明的范围，本发明的范围通过权利要求限定。
当结合附图考虑时，从下列用于实施本发明教导的最佳模式的详细说明中，本发明的上述特征以及有利之处以及其它特征和有利之处是显而易见的。
参照附图，其中在全部几幅视图中，相图的附图标记指代相同的部件，图1示出了使用在鞋类物品的中底内的气囊元件10。气囊元件10具有第一或上聚合物片12以及第二或下聚合物片14。
多维编织拉伸元件16被设置在内腔17中，内腔17形成在上片12和下片14之间，如图4和5所示。拉伸元件16具有通过多个拉伸元件22互连的第一内片18和第二内片20。在成品的气囊元件10中，内片18被焊接到上片12并且内片20被焊接到下片14，如图5所示。一经发生焊接，拉伸元件22由此可操作地连接到上片12和下片14。图4示出了在焊接之前的拉伸元件16。
气囊元件10是拉伸元件16的设置的非限制性示例。在其它实施例中，气囊元件10可以不具有拉伸元件。在其它实施例中，拉伸元件16可以具有其它结构，在该结构中仅拉伸元件16的选定部分被焊接到上片12或下片14以实现所需的三维结构。在授予Potter等人的美国专利号为5,802,739的专利中示出和说明了具有各种拉伸元件配置的多个气囊元件，通过引用将其全部内部结合于此。拉伸元件和/或加强结构可以与气囊元件10整合，以提供所需的响应能力，如Rudy等人在美国专利号为4,906,502以及Swigart等人在美国专利号为8,061,060的专利中所公开的，在此通过引用将其全部内容结合于此。
气囊元件10可以由多种材料制成，包括能够弹性地保留如空气或另一气体的流体的各种聚合物。用于气囊元件10的聚合物材料的示例包括热塑性聚氨酯、聚氨酯、聚酯、聚酯型聚氨酯和聚醚型聚氨酯。而且，气囊元件10可以由不同材料层形成。在一个实施例中，气囊元件10由具有一个或多个热塑性聚氨酯(TPU)层的薄膜制成，该热塑性聚氨酯层具有对于包含在其内的加压流体不可渗透的乙烯和乙烯醇的共聚物(EVOH)的一个或多个壁障层，如Bonk等人在美国专利号为6,082,025的专利中公开的，通过引用将其全部内容结合于此。气囊元件10也可以由包括热塑性聚氨酯以及乙烯和乙烯醇的共聚物的交替层的材料制成，如Mitchell等人在美国专利号为5,713,141和5,952,065的专利中所公开的，通过引用将其全部内容结合于此。可选地，该层可以包括乙烯和乙烯醇的共聚物、热塑性聚氨酯以及乙烯和乙烯醇的共聚物与热塑性聚氨酯的再研磨材料。气囊元件10也可以是柔性的微层膜(microlayer membrane)，该微层膜包括气体壁障材料和弹性体材料的交替层，如Bonk等人在美国专利号为6,082,025和6,127,026的专利中所公开的，通过引用将其全部内容结合于此。用于气囊元件10的另外合适的材料在Rudy发明的美国专利号为4,183,156和4,219,945的专利中进行了公开，通过引用将其全部内容结合于此。用于气囊元件16的进一步合适的材料包括含有结晶材料的热塑性膜，如Rudy在美国专利号为4,936,029和5,042,176的专利中所公开的，以及包括聚酯多元醇的聚氨酯，如Bonk等人在美国专利号为6,013,340、6,203,868以及6,321,465中所公开的，通过引用将其全部内容结合于此。在选择关于气囊元件10的材料时，可以考虑如拉伸强度、拉伸性能、疲劳特性、动态模量和损耗角正切的工程特性。可以选择用于形成气囊元件10的材料板的厚度以提供这些特性。气囊元件10是弹性的并且提供可调整的缓冲和柔性，例如通过选择加压水平。拉伸元件和/或加强结构可以与气囊元件16整合以提供所需的响应性，如Rudy等人在美国专利号为4,906,502以及Swigart等人在美国专利号为8,061,060的专利中所公开的，通过引用将其全部内容结合于此。
拉伸元件16与第一片18和第二片20的焊接是异形物体(即气囊元件10)所需的异形焊缝的一个示例。在图4和图5中示出和描述了加工工具总成30，并且图6的制造方法100可以以有效和可靠的方式提供这样的异形焊缝。在将拉伸元件16射频焊接到上片12和下片14之前，上片12和下片14在外围凸缘32处焊接到一起，如图1和4所示。如图1和4中可以看出的，下片14具有异形外表面34。鞋跟区域36尤其具有相对大的缓冲部分38。在图1和4两者中，示出了通过向内腔增加空气或另外的气体以使气囊元件10充气之前的气囊元件10。相应地，异形外表面34由上片12和下片14的热成型而产生，并且甚至是在气囊元件10最终充气之前存在。
加工工具总成30配置为通过使用能够容易并且可靠地贴合到异形外表面34的部件来实现如气囊元件10的异形物体的射频焊接。加工工具总成30包括如图2所示的至少一个金属丝网筛40，以及如图3所示的至少一个非介电的弹性可变形部件42。虽然在图2的实施例中使用了仅一个金属丝网筛40，但可以使用多个金属丝网筛。金属丝网筛40和非介电的弹性可变形部件42是相对软的加工工具，该加工工具与加工工具总成30的更刚性的第一成型工具44和第二成型工具46一起使用，从而实现这里所述的独特和可靠的射频焊接程序。
金属丝网40可以是能够与第一成型工具44配合的多种材料中的任何一种，以在射频能量被提供到第一成型工具44时引起气囊元件10内的交变磁场，第一成型工具44充当电极。例如，金属丝网筛40可以是青铜、黄铜、铜、不锈钢或这些材料的任何合金。此外，用于金属丝网筛40的网格大小的范围是合适的。例如，每平方英寸网格具有120乘120的金属丝以及每平方英寸网格具有500乘500的金属丝的金属丝网筛40被确定为合适的。然而，金属丝网筛40可以具有比那些尺寸更小或更大的网格尺寸。如图2和图4中所示，在没有承受成型工具44、46之间的压缩时，金属丝网筛40总体是平的。然而，金属丝网筛40配置为具有在承受成型工具44、46之间的压缩时使金属丝网40容易弯曲以贴合到气囊元件10的异形外表面34的金属丝厚度和网格。
图3的非介电的弹性可变形部件42是弹性并且弹性可变形的材料的。换言之，该部件42具有承受成型工具44、46的压缩时的顺应性以使其贴合到下成型工具46的上表面48，并且将金属丝网部件40压缩为抵靠气囊元件10的异形外表面34，同时占用金属丝网部件40和上表面48之间的不规则的空间，如图5中所示。下成型工具46的上表面48具有一些异形区域，该区域总体对应于气囊元件10的异形外表面34。然而由于部件42容纳了表面48、34的形貌上的差异，因此成型工具46的轮廓不如气囊元件的轮廓那么尖锐。实际上，下成型工具46的表面48可以是完全平坦的。虽然在图3的实施例中示出了仅一个非介电的弹性可变形部件42，但可替代地可以使用多个相邻的非介电的弹性可变形部件42。
部件42在不被压缩时可以大体是矩形形状，如图3中所示的，其具有大体均匀的厚度T1。厚度T1被选定为使部件42能够在与第二成型工具46以及金属丝网40接触的全部区域上被压缩。例如，部件42的一些部分可以被压缩到厚度T2，并且其它部分可以被压缩到甚至更大的厚度T3，两者都小于未被压缩的厚度T1。
当被压缩时，在部件42弹性地偏置到它的原始形状和厚度T1时，部件42的材料使部件42产生抵抗压缩力而作用的偏置力。用于部件42的合适的材料包括但不限于聚合物泡沫、橡胶、泡沫橡胶和硅丁基橡胶。这些合适的材料是非介电的，以使部件42实现将第二成型工具46与提供到第一成型工具44的射频能量的影响隔离。相应地，部件42不仅用于推动金属丝网筛40贴合到气囊元件10的异形外表面34，也可以确保金属丝网部件40用作与第一成型工具44配对的部件，从而在气囊元件10的材料内产生交变磁场。
图5示出了第一成型工具44，例如通过施加压力使第一成型工具44移动到更接近第二成型工具46，施加压力包括但不限于通过产生力F的活塞50的气动或液压压力，如本领域技术人员所理解的。由此，第一成型工具44可操作用于朝向第二成型工具46移动以及移动离开第二成型工具46。第二成型工具46可以被固定，以使其静止。在其它实施例中，成型工具44、46两者都可以配置为朝向彼此移动和移动离开彼此，或者活塞50可以被连接到第二成型工具46并且仅第二成型工具46可以配置为朝向第一成型工具44移动以及移动离开第一成型工具44。
第一成型工具44可操作地连接到电源52，电源52向第一成型工具44提供射频能量，例如当开关54闭合时。第一成型工具44是导电的，例如铁磁材料。第一成型工具44接触第一片12的上表面56并且金属丝网工具40贴合到第二片14的异形表面34并且与之接触，如本发明所述。
射频能量在第一成型工具44和金属丝网部件40之间并且因此在气囊元件10内产生交变磁场。交变磁场激发片12、14的介电材料，将它们熔接到拉伸元件16的第一内片18和第二内片20。由于第一片12的整个上表面与第一成型工具44接触，并且第二片14的异形下表面34与金属丝网部件40接触，因此，内片18、20的整个外表面被焊接到片12、14的内表面，包括异形焊缝W1部分。焊缝W1是气囊元件10的第一部分(即拉伸元件16)与气囊元件的第二部分(即片14)的。由射频能量所产生的如焊缝W1的焊缝可以加热材料，使材料混合，熔接彼此焊接的两个部件的材料并且由此使其如同任何一种材料一样牢固。
图6是说明制造如用于鞋类物品的气囊元件10的部件的方法100的流程图。该方法100可以在步骤102开始，在第一成型工具44和第二成型工具46之间压缩非介电的弹性可变形部件42、金属丝网部件40以及介电的异形物体(气囊元件10)。方法100之后继续到步骤104，向第一成型工具44提供射频能量，由此引起第一成型工具44和金属丝网部件40之间的射频电磁场，该射频电磁场产生气囊元件10的异形焊缝W1。在预定时间量之后或者在一些其它预定参数已经实现之后，方法100移动到步骤106并且停止射频能量，或者换言之，例如通过断开开关54而不再向第一成型工具44提供射频能量。
当射频能量停止时，在步骤108中，通过第一成型工具44和第二成型工具46使非介电的弹性可变形部件42、金属丝网部件40以及介电的异形物体(气囊元件10)的压缩保持至少预定的时间量。在该时间期间，在步骤110中，气囊元件10冷却并且压力被释放，容许使第一成型工具44移动离开第二成型工具46。在步骤112中，被焊接的异形物体——即气囊元件10——之后从成型工具46、48之间移除。在步骤114中，气囊元件10被充气。充气可以发生在步骤112的移除之前或之后。
图7示出了用于鞋类物品219(在图10中示出)的另一气囊元件210，可以根据使用图9和10的加工工具总成230的图8的制造方法300来焊接该气囊元件。气囊元件210在气囊元件210的外侧213和内侧215部分之间的鞋跟区域内形成腔211。气囊元件210由与关于气囊元件10所描述的任何材料形成的第一片212和第二片214(图9中示出)形成。第一片212形成气囊元件210的整个上表面，并且第二片214形成气囊元件210的整个下表面。第一片212和第二片214在围绕腔211的外围凸缘232A和凸缘232B处被焊接在一起。加工工具总成230包括第一成型工具244和第二成型工具246。第一成型工具244可朝向第二成型工具246移动以及移动离开第二成型工具246，例如通过使用产生力F的活塞250施加的气动或液压力。第一成型工具244由此可操作为朝向第二成型工具246移动以及移动离开第二成型工具246。第二成型工具246可以被固定，以使其静止。在其他实施例中，成型工具244、246两者都可以配置为朝向彼此移动和移动离开彼此，或者活塞250可以被连接到第二成型工具246并且仅第二成型工具246可以配置为朝向第一成型工具244移动以及移动离开第一成型工具244。
加工工具总成230也包括如图9和10所示的第一金属丝网筛240A和第二金属丝网筛240B以及至少一个非介电的弹性可变形部件242。两个单独的金属丝网筛240A、240B被用在图9和10的实施例中。使用多个金属丝网筛有助于焊接具有复杂轮廓的物体，例如气囊元件210的单独的表面234A、234B。可选地，作为替代，可以使用在外侧和内侧213、215两者下方延伸的仅一个金属丝网筛，或者可以使用多于两个金属丝网筛。类似地，虽然仅一个非介电的弹性可变形部件242被用在图9和10的实施例中，但可替代地可以使用多个非介电的弹性可变形的部件。金属丝网筛240A、240B和非介电的弹性可变形部件242是与加工工具总成230的更刚性的第一成型部件244和第二成型部件246一起使用的相对软的加工工具，从而实现这里所述的独特并且可靠的射频焊接程序。
金属丝网筛240A、240B可以是能够与第一成型工具244配合的多种材料中的任何一种，以在向第一成型工具244提供射频能量时在气囊元件210内产生交变磁场，第一成型工具244可以作为电极。例如，金属丝网筛240可以是青铜、黄铜、铜、不锈钢或这些材料的任何合金。此外，用于金属丝网筛240A、240B的网格大小的范围是合适的。例如，每平方英寸网格具有120乘120的金属丝以及每平方英寸网格具有500乘500的金属丝的金属丝网筛240A、240B被确定为合适的。然而，金属丝网筛240A、240B可以具有比那些尺寸更小或更大的网格尺寸。如图9中所示，在没有承受成型工具244、246之间的压缩时，金属丝网筛240A、240B总体是平的。然而，金属丝网筛240A、240B配置为具有在承受成型工具244、246之间的压缩时使金属丝网筛240A、240B容易弯曲以贴合到气囊元件210的外侧和内侧部分213、215的异形外表面234A、234B的金属丝厚度和网格。
图9的非介电的弹性可变形部件242是弹性并且弹性可变形的材料。换言之，该部件242在承受成型工具244、246压缩时具有顺应性(compliant)，该顺应性使其贴合到下成型工具246的上表面248，并且将金属丝网部件240A、240B压缩为抵靠气囊元件210的下表面234A、234B，同时占用金属丝网部件240A和240B与下表面234A、234B之间的不规则的空间，如图10中所示。下成型工具242的上表面248具有一些异形区域，该区域总体对应于气囊元件210的异形外表面234A、234B。然而由于部件242容纳了表面248以及234A、234B的形貌上的差异，因此成型工具246的轮廓不如气囊元件210的轮廓那么尖锐。事实上，下成型工具246的表面248可以是完全平坦的。
部件242可以是具有大体均匀厚度T4的大体矩形形状，类似于部件42。厚度T4被选定为使部件242能够在与第二成型工具246以及金属丝网部件240A、240B接触的全部区域上被压缩。例如，部件242的一些部分可以被压缩到厚度T5，并且其它部分可以被压缩到甚至更小的厚度T6，两者都小于未被压缩的厚度T4。
当被压缩时，在部件242弹性地偏置到图9的它的原始形状和厚度T4时，部件242的材料使部件242产生抵抗压缩力而作用的偏置力。用于部件242的合适的材料包括但不限于聚合物泡沫、橡胶、泡沫橡胶和硅丁基橡胶(silicone butyl rubber)。这些合适的材料是非介电的，以使部件242实现将第二成型工具246与提供到第一成型工具244的射频能量的影响隔离。相应地，部件242不仅用于推动金属丝网240A、240B贴合到气囊元件210的异形外表面234A、234B，也可以确保金属丝网部件240A、240B用作与第一成型工具244配对的部件，从而产生交变磁场。
鞋面270例如通过夹具272夹持或以其它方式固定到第一成型工具244。第一成型工具244形状设置为与鞋面270配合，类似于鞋楦。鞋面270的外表面274是异形表面，通过射频焊接将鞋面片212的异形表面276A、276B焊接到该异形表面。虽然图9和10的实施例示出了被焊接到气囊元件210的鞋面270，但在其它实施例中，其它部件可以被焊接到气囊元件210的外表面。
图10示出了第一成型工具244，例如通过施加如包括但不限于由产生力F的活塞250的气动或液压压力的压力将该第一成型工具244移动为更接近第二成型工具246，如本领域技术人员所理解的。第一成型工具244由此可操作为朝向第二成型工具246移动和移动离开第二成型工具246。第二成型工具246可以被固定以使其静止。在其它实施例中，成型工具244、246两者都可以配置为朝向彼此移动和移动离开彼此，或者活塞250可以被连接到第二成型工具246并且仅第二成型工具246可以配置为朝向第一成型工具244移动以及移动离开第一成型工具244。
第一成型工具244可操作地连接到电源52，电源52向第一成型工具244提供射频能量，例如当开关54闭合时。第一成型工具244是导电的，例如铁磁材料。当第一成型工具244朝向第二成型工具246移动时，鞋面270接触第一片212的外侧和内侧部分213、215的上表面276A、276B并且金属丝网工具240A、240B贴合到第二片214的异形表面234A、234B并且与之接触，如本发明所述。
由电源52提供的射频能量在第一成型工具244和金属丝网部件240A、240B之间并且因此在气囊元件210内产生交变磁场。交变磁场激发片212的介电材料，将表面276A、276B熔接到鞋面270。由于整个面276A、276B与鞋面270接触并且第二片214的异形下表面234A、234B与金属丝网部件240A、240B接触，因此，在第一部件(第一片212)以及第二部件(鞋面270)之间形成异形焊缝W2、W3。
图8的流程图示出了用于生产如鞋类物品219的部件的方法300，鞋类物品219包括气囊元件210和鞋面270。该方法300可以通过步骤302开始，使气囊元件210充气，并且之后是步骤304，在第一成型工具244上设置鞋面270。鞋面270例如通过夹具272被固定到第一成型工具244。
在步骤306中，在第一成型工具244和第二成型工具246之间压缩非介电的弹性可变形部件242、金属丝网部件240A和240B以及介电的异形物体(气囊元件210)。方法300之后继续到步骤308，向第一成型工具244提供射频能量，由此引起第一成型工具244和金属丝网部件240A、240B之间的射频电磁场，该射频电磁场产生气囊元件210与鞋面270的异形焊缝W2、W3。在预定时间量之后，或当一些其它的预定参数已经取得，方法300移动到步骤310并且停止射频能量，或者换言之，例如通过断开开关54从而不再向第一成型工具244提供射频能量。
当射频能量停止时，在步骤312中，通过第一成型工具244和第二成型工具246使非介电的弹性可变形部件242、金属丝网部件240A和240B以及介电的异形物体(气囊元件210)的压缩保持至少预定的时间量。在该时间期间，在步骤314中，气囊元件210冷却并且压力被释放，容许使第一成型工具244移动离开第二成型工具246。在步骤316中，被焊接的异形物体——即其上焊接有鞋面270的气囊元件210——之后从成型工具244、246之间移除。这需要松开鞋面270并且将鞋面从第一成型工具244移除。
虽然与用于鞋类物品的气囊元件10、210的射频焊接相关地示出和描述了方法100和300，但方法100和300可以用于需要异形焊缝的其它介电物体的射频焊接。
虽然详细描述了用于实施当前教导的诸多方面的最佳模式，但熟悉与这些教导相关领域的人员可以明白在所附权利要求的范围之内的用于实施当前教导的各种可选方面。

Claims (20)

1.一种通过射频焊接制造介电的异形物体的方法，包含：
在第一成型工具和第二成型工具之间压缩非介电的弹性可变形部件、金属丝网部件以及介电的异形物体，其中所述异形物体位于所述第一成型工具和所述金属丝网部件之间，并且其中所述弹性可变形部件位于所述金属丝网部件和所述第二成型工具之间；
其中所述压缩是利用足够的压力，以使所述弹性可变形部件弹性变形并且所述金属丝网部件被所述弹性可变形部件柔性地压缩为抵靠所述异形物体的异形表面；以及
向所述第一成型工具提供射频能量，由此产生位于所述第一成型工具和所述金属丝网部件之间的射频电磁场，所述射频电磁场引起所述异形物体的异形焊缝；
其中所述金属丝网部件是第一金属丝网部件并且所述异形焊缝是第一异形焊缝；其中所述压缩包括在所述弹性可变形部件和所述异形物体之间压缩第二金属丝网部件；并且其中所述第二金属丝网部件与所述第一金属丝网部件隔开以使所述提供射频能量引起所述异形部件的第二异形焊缝。
2.根据权利要求1所述的方法，其中所述第一异形焊缝是所述异形物体的第一部分与所述异形物体的第二部分的焊缝。
3.根据权利要求1所述的方法，进一步包含：
在所述第一成型工具和所述异形物体之间设置第二部件；并且
其中所述第一异形焊缝是所述异形物体与所述第二部件之间的焊缝。
4.根据权利要求3所述的方法，其中所述异形物体是用于鞋类物品的气囊元件；其中所述第二部件是用于鞋类物品的鞋面；并且进一步包含：
在所述压缩之前使所述气囊元件充气。
5.根据权利要求1所述的方法，其中所述弹性可变形部件支撑在所述第二成型工具上，所述金属丝网部件支撑在所述弹性可变形部件上，并且进一步包含：
停止提供所述射频能量；
在停止提供所述射频能量之后将所述弹性可变形部件、所述金属丝网部件和所述异形物体的压缩保持至少预定时间量；
通过使所述第一成型工具移动离开所述第二成型工具或者使所述第二成型工具移动离开所述第一成型工具或者两者都有地释放所述弹性可变形部件、所述金属丝网部件和所述异形物体上的压力；以及
从所述成型工具之间移除被焊接的所述异形物体。
6.根据权利要求5所述的方法，其中所述异形物体是用于鞋类物品的气囊元件；并且进一步包含：
使所述气囊元件充气。
7.根据权利要求6所述的方法，其中所述第一异形焊缝是所述气囊元件的外片与所述气囊元件中的内部编织元件的焊缝；以及
其中所述使所述气囊充气发生在从所述成型工具之间移除被焊接的所述异形物体之后。
8.根据权利要求4所述的方法，其中所述第一异形焊缝是所述气囊元件的至少一个片的焊缝。
9.根据权利要求8所述的方法，其中所述第一异形焊缝是所述气囊元件的所述至少一个片与所述气囊元件内的内部编织元件的焊缝；并且进一步包含：
从所述成型工具之间移除被焊接的所述气囊元件；以及
在从所述成型工具之间移除被焊接的所述气囊元件之后使所述气囊元件充气。
10.根据权利要求8所述的方法，其中所述第一异形焊缝是所述气囊元件的所述至少一个片与所述鞋类物品的鞋面的焊缝；并且进一步包含：
在所述压缩之前将所述鞋类物品的鞋面放置在所述第一成型工具和所述气囊元件之间；以及
在所述压缩之前使所述气囊元件充气。
11.一种用于通过射频焊接制造介电的异形物体的加工工具总成，所述总成包含：
第一成型工具和第二成型工具，所述第一成型工具和所述第二成型工具中的至少一个配置为可朝向另一个移动以及移动离开另一个；
支撑在所述第二成型工具上的非介电的弹性可变形部件；
支撑在所述非介电的弹性可变形部件上的金属丝网部件；其中所述第一成型工具和所述金属丝网部件配置用于向介电的异形物体传输射频能量，所述介电的异形物体通过如下方式被压缩在所述第一成型工具和所述金属丝网部件之间，即，通过使所述至少一个成型工具移动向另外的成型工具，并且通过使所述弹性可变形部件弹性地变形以将所述成型工具的压力分布在所述金属丝网部件上，以抵靠所述介电的异形物体的异形表面柔性地压缩所述金属丝网部件，从而提供所述异形物体的异形焊缝；
其中所述金属丝网部件是第一金属丝网部件并且所述异形焊缝是第一异形焊缝；并且进一步包含：
支撑在所述至少一个非介电的弹性可变形部件上的第二金属丝网部件；其中所述第二金属丝网部件与所述第一金属丝网部件隔开；其中所述第一成型工具和所述第二金属丝网部件配置用于向所述介电的异形物体传输射频能量以提供所述异形物体的第二异形焊缝。
12.根据权利要求11所述的加工工具总成，其中所述非介电的弹性可变形部件是聚合物泡沫以及丁基橡胶中的一种。
13.根据权利要求12所述的加工工具总成，其中所述聚合物泡沫是泡沫橡胶。
14.根据权利要求11-13中任一项所述的加工工具总成，其中所述金属丝网部件是铜和不锈钢中的一种或其合金。
15.根据权利要求14所述的加工工具总成，所述铜为青铜和/或黄铜。
16.根据权利要求11所述的加工工具总成，其中所述金属丝网部件具有每英寸120乘120的金属丝到每英寸500乘500的金属丝。
17.根据权利要求11所述的加工工具总成，其中所述非介电的弹性可变形部件具有支撑所述金属丝网部件的表面；并且其中所述表面在没有在所述成型工具之间被压缩时是大体平坦的。
18.根据权利要求11所述的加工工具总成，其中所述非介电的弹性可变形部件是顺应性的并且所述金属丝网部件具有柔性，所述柔性使得所述金属丝网部件在预定压力下被压缩时贴合到所述异形表面。
19.根据权利要求11所述的加工工具总成，所述总成与所述介电的异形物体组合；并且其中所述介电的异形物体是可充气的气囊元件，所述可充气的气囊元件具有至少部分的热塑性聚氨酯(TPU)片。
20.根据权利要求19所述的加工工具总成，所述总成与所述介电的异形物体组合，并且进一步与鞋面组合；并且其中所述第一异形焊缝位于所述鞋面和所述气囊元件之间。
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