GB2475886A - Method of welding sheet material - Google Patents

Method of welding sheet material Download PDF

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Publication number
GB2475886A
GB2475886A GB0921253A GB0921253A GB2475886A GB 2475886 A GB2475886 A GB 2475886A GB 0921253 A GB0921253 A GB 0921253A GB 0921253 A GB0921253 A GB 0921253A GB 2475886 A GB2475886 A GB 2475886A
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GB
United Kingdom
Prior art keywords
sheets
tool
welding
cutting
angle
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB0921253A
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GB0921253D0 (en
Inventor
David Beer
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
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Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to GB0921253A priority Critical patent/GB2475886A/en
Publication of GB0921253D0 publication Critical patent/GB0921253D0/en
Publication of GB2475886A publication Critical patent/GB2475886A/en
Withdrawn legal-status Critical Current

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Classifications

    • 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
    • B29C66/739—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 material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—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 material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—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 material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
    • B26D7/00—Details of apparatus for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
    • B26D7/08—Means for treating work or cutting member to facilitate cutting
    • B26D7/086—Means for treating work or cutting member to facilitate cutting by vibrating, e.g. ultrasonically
    • 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
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • 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
    • B29C65/74—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area
    • B29C65/743—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc
    • 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
    • B29C65/74—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area
    • B29C65/743—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc
    • B29C65/7443—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc by means of ultrasonic vibrations
    • 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
    • B29C66/40—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
    • 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
    • B29C66/735—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 extensive physical properties of the parts to be joined
    • B29C66/7352—Thickness, e.g. very thin
    • B29C66/73521—Thickness, e.g. very thin of different thickness, i.e. the thickness of one of the parts to be joined being different from the thickness of the other part
    • 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
    • B29C66/81415—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 bevelled
    • 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
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
    • B26D1/00—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor
    • B26D1/0006—Cutting members therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
    • B26D1/00—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor
    • B26D1/01—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work
    • B26D1/04—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a linearly-movable cutting member
    • B26D1/06—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a linearly-movable cutting member wherein the cutting member reciprocates
    • B26D1/08—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a linearly-movable cutting member wherein the cutting member reciprocates of the guillotine type
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
    • B26D7/00—Details of apparatus for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
    • B26D7/08—Means for treating work or cutting member to facilitate cutting
    • B26D7/10—Means for treating work or cutting member to facilitate cutting by heating
    • 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
    • B29C66/03—After-treatments in the joint area
    • B29C66/032—Mechanical after-treatments
    • B29C66/0324—Reforming or reshaping the joint, e.g. folding over
    • B29C66/03241—Flattening
    • B29C66/03242—Flattening of sheets being positioned in abutment, e.g. after folding open of an overlap joint
    • 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
    • B29C66/116—Single bevelled joints, i.e. one of the parts to be joined being bevelled in the joint area
    • B29C66/1162—Single bevel to bevel joints, e.g. mitre 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
    • B29C66/70—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
    • B29C66/71—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 composition of the plastics material of the parts to be joined
    • 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
    • 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
    • B29C66/81415—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 bevelled
    • B29C66/81419—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 bevelled and flat

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Forests & Forestry (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

A tool (16) for butt-welding two thermoplastic sheets (10, 11) together and a method of welding comprising the steps of(a) providing two sheets of thermoplastic weldable materials (10, 11) each having a first surface (12 and a second surface(11);(b) bringing the two sheets of materials together with their first surfaces (12) confronting each other;(c) positioning an edge of the sheets (10, 11) adjacent a predetermined line;(d) contacting the two sheets (10, 11) with a cutting and welding tool (16) that has an inclined welding surface (18) and a cutting edge (17) that extend in a direction along said predetermined line;(e) urging the tool (16) in a direction towards the two sheets (10, 11) to bring the inclined surface (18) into contact with the two sheets (10, 11), and generating heat so as to melt and fuse the sheets (10, 11) together along said line whilst simultaneously cutting through the two sheets (10,11); and(f) unfolding the two sheets (10, 11) to form a unitary article having the two sheets butt welded along said line with their first surfaces (12) facing in a common direction. The step of generating heat is effected by either means of a radio frequency welding process and the tool (16) constitutes one electrical conductor of a pair of opposing conductors (16, 19) between which an electromagnetic field is generated, or by an ultrasonic welding process where the tool (16) constitutes a horn of an ultrasonic welding machine, and the sheets (10, 11) are positioned between the horn (16) and an anvil (19) of the machine.

Description

METHOD OF WELDING SHEET MATERIAL
THTS TNVENTION relates to a method and apparatus for welding together flexible sheets of weldable materials, and is particularly, although not exclusively, is concerned with welding together plastic sheet materials.
There is a need to be able to butt weld together thin sheets of plastic materials with an aesthetic join.In the manufacture of badges, decorative indicia, and labels for clothing, and also in the production high visibility signs for advertising and providing information or directions, The term "sheet" as used in the present application is taken to include a monolithic layer or multiple layers of plastics materials that are laid up to form a laminated sheet. The sheets to be butt welded together need not be of identical materials providing that they can be welded or fused together with the application of heat by means of radio frequency or ultrasonic welding apparatus, as will be explained hereinafter.
According to the present invention there is provided a method of butt-welding two thermoplastic sheets together comprising the steps of (a) providing two sheets of thermoplastic weldable materials each having a first surface and a second surface; (b) bringing the two sheets of materials together with their first surfaces confronting each other; (c) positioning an edge of the sheets adjacent a predetermined line; contacting the two sheets with a cutting and welding tool that has an inclined welding surface and a cutting edge that extend in a direction along said predetermined line; (d) urging the tool in a direction towards the two sheets to bring the inclined surface into contact with the two sheets and generating heat so as to melt and fuse the sheets together along said line whilst simultaneously cutting through the two sheets; and (e) unfolding the two sheets to form a unitary article having the two sheets butt welded along said line with their first surfaces facing in a common direction.
The step of generating heat may be effected by means of a radio frequency welding process and the tool constitutes one electrical conductor of a pair of opposing conductors between which an electromagnetic field is generated. Alternatively, the tool may constitute a horn of an ultrasonic welding machine, the sheets to be welded are positioned between the horn and an anvil of the machine, and the step of generating heat is effected by means of an ultrasonic energy welding process.
Preferably the inclined surface of the tool extends away from the cutting edge at an angle 0 relative to a second surface of the tool that extends in a direction substantially perpendicular from the cutting edge.
Preferably the cutting edge of the tool is in the range of 0.05mm (50 t) to 0.15mm (150 t) wide.
Where the combined thickness (t) of the two sheets to be welded when in the position in step (b) of the method of claim 1 is in the range of 2.0 mm to 1.0 mm, and the angle ® of the tool is in the range of 25 ° to 30°, and ideally the angle 1 is 30°.
Where the combined thickness (t) of the two sheets is in the range of 1.0 mm to 0.5 mm the angle 0 is preferably in the range of° 30 to 45° and ideally the angle 0 is 45°.
Where the combined thickness of the two sheets in the range of 0.5mm to 0.1mm and the angle 0 is in the range of 45° to 600, and ideally the angle 0 is 60°.
According to another aspect of the present invention there is provided a welded product wherein the weld is made by the method of welding according to the present invention.
According to a further aspect of the present invention there is provided a welding apparatus incorporating a tool constructed in accordance with the present invention.
Preferably the first faces of the sheets constitute the front surface of the sheets and the second faces constitute the back surface of the sheets. Alternatively the first faces constitute the back surface of the welded sheets and the second faces of the sheets constitute the front surface of the welded sheets.
The present invention will now be described, by way of an example, with reference to the accompanying drawings in which:-Figure 1 shows schematically two sheets of thermoplastic materials to be welded together; Figure 2 shows a cross sectional side view of the two sheets of materials of figure 1 (not to scale) laid up on a table of a radio frequency welding machine prior to cutting and welding; Figure 3 shows a cross sectional side view of the two sheets of materials of figure 1 (not to scale) that have been welded together using the a radio frequency welding machine shown in Figure 2 and shows schematically the position of the welding tool after the sheets have been cut and welded; Figure 4 shows a cross sectional side view of the welding tool of the present invention; Figure 5 shows the step of unfolding the sheets after welding (the dotted lines and the final welded article after welding the sheets shown in Figures 1 to 4.
Referring to Figure 1 there is shown two sheets of thermoplastic materials 10, 11 such as, for example, PVC that are to be welded together. Each of the sheets 10, 1 1 has a first face 12 on which has been printed indicia or decorative matter, and a second face 13 (back face).
For simplicity, in the present example, each sheet is a monolithic layer, but one or both sheets or 11 could be made of two or more layers that are laid up to form a unitary laminated sheet.
Referring to Figure 2 the first sheet 10 is placed on a surface of a table 14 of a radio frequency welding machine, or ultrasonic welding machine, as will be explained in more detail below, with its first face 12 facing away from the table 14 and its second face 13 resting on the table 14. The second sheet 11 is then laid onto the first sheet 10 with its first face 12 facing that of the first 11. The edges of the two sheets 10, 11 adjacent to where the join line is to be formed, are aligned to reduce waste as shown in Figure 2, and if desired can be clamped in position during welding by means of an optional clamping plate 15 that stops the sheets 10 and 11 moving relative to each other on the table 14.
A cutting and welding tool 16 constructed in accordance with the present invention is used to perform the tasks of cutting through the two sheets 10 and 11 and simultaneously welding them together. The tool 16 is offered up to the assembled sheets 10, 11 and advanced towards the sheets 10 and 11 as shown in Figure 3. The welding tool 16 has a cutting edge 17 and an inclined surface 18.
For simplicity, the method of welding now described makes use of a radio frequency welding machine but where the context suits the invention is also applicable to ultrasonic welding. In the context of a radio frequency welding, the tool 16 constitutes one of two conductors of the radio frequency welding machine (sometimes referred to as dielectric or high frequency welding), that fuses the two sheets 10, 11 by applying radio frequency energy (usually in the range of 13 to 100MHz electromagnetic field) between the tool 16 and a second conductor 19. The tool 16 is used to bond the sheets 10. 11 and simultaneously create a tear-sealed dressed edge in one operation. The tool 16 is preferably made of brass or magnesium as these metals are the most efficient for transmission of high frequency radio waves or ultra-sonic vibration. Similarly, the conductor 19 is made of brass or magnesium.
Other less efficient metals can be used instead of brass or magnesium.
Radio Frequency welding relies on certain properties of the materials being welded to cause generation of heat in a rapidly alternating electric field between the two conductors 16, 19. The two conductors 16, 19 act as pressure applicators during heating and cooling of the materials to be welded, and the dynamic electric field causes molecules in polar thermoplastics to oscillate and cause heating of the plastics materials. Polyvinylchloride (PVC) and polyurethane are the most common materials that can be welded, but it is possible to weld other polymers such as Nylon (Registered Trade Mark) Polyethylene terephthalate (PET), Ethylene Vinyl Acetate (EVA) and some Acrylonitrile butatdiene styrene resins (ABS) ABS resins.
When joining two sheets 10, 11 of different thickness the strongest bond between the two sheetsl0 and 11, and most efficient use of machine settings (e.g. minimum time, dwell, heat, pressure and power settings) is achieved with the thinner of the sheets 11 being laid on top of the thicker sheet 10 so that it is contacted by the inclined surface 18 and cutting edge 17 of the welding tool 16.
The cross sectional shape of the tool 16 is shown in Figure 4 and differs significantly from that used in the past for radio frequency welding of plastics or that used in ultrasonic welding processes. Whereas in the past, the two conductors 15 and 19 usually have confronting flat surfaces that squeeze the sheets 10. 1 1 to be welded between them, the tool of the present invention has no significant surface extending parallel to the sheets 10, 11 (as would be the usual case with prior known tools). Instead, the tool 15 of the present invention comprises a perpendicular rear face 20 and a sloping or angled face 18 that defines the bonding and cutting faces of the tool 15. The two surfaces 18 and 20 meet at the cutting tip 17. However the tip 17 need not be a sharp cutting edge (although it could be) but can have a thin flat face 23 extending normal to that of the rear face 20. However, unlike welding tools used in the past, this flat face 23 should be in the range of 0.05mm (50t) to 0.15mm (150 t) wide and preferably no more than about 0.05 mm (50 t) wide, so as to achieve the cleanest tear seal edge possible. This ensures that the finished surface of the weld is smooth and free of irregularities.
During welding the bonding of the two sheets 10, 11 is achieved by the transference of radio frequency or ultrasonic energy from the angled face 18 only.
The angle 0 subtended by the inclined face 18 and the perpendicular rear face 20 is calculated in relation to the combined thickness "t" of the two sheets so as to cause melting of the sheets 10, 11 throughout the double thickness.
The thinner that the combined thickness (t) of the two sheets 10, 11 being bonded is, the larger will be the subtended angle 0 of the angled face 18. This ensures that a successful bond of sufficient strength will be obtained. Trials have shown the following bonding face angles 0 to be the most appropriate.
Combined Thickness Range of Cutting Preferred angle 0 of the sheets 10 and 11 Angles 0 Preferred angle 2.0mm to 1.0 25°to3O° 300 1.Omm-0.5rrirn 30°to45° 450 0.5 mmto 0.1 mm 45° to 60° 60° These figures have shown to be most suitable when bonding materials of similar flexibility (that is of similar plasticizer content) and show that the thinner the combined thickness (t) of sheets 10 and lithe greater will need to be the angle 0. Thus during welding the inclined surface 18 of the tool needs to compress the thinner materials more than the thicker materials. Where materials are less compatible, there may be a need to adjust the weld face angle 0 accordingly to achieve acceptable bond quality.
II will be appreciated that both sheets 10, 11 are effectively welded from the rear of the sheets and ii and have a sloping weld face defined by the angle of the inclined face 18 of the tool. To complete the weld, the two sheets 10, ii are then unfolded about the weld line to form a unitary article (shown in Figure 6) that is effectively butt-welded together along a relatively straight line but has the first surfaces 12 of the sheets 10 and ii facing in a common direction. This creates an article which when viewed from the front has an aesthetic join line.
Ultrasonic welding of plastics has been in use for many years for welding thermoplastics and this invention is also applicable to ultrasonic welding of the sheets 10 and ii using a similar shaped tool 16 as that described above. In the process of ultrasonic welding a thermal rise in the bonding area is produced by the absorption of mechanical vibrations produced in the sheets 10 and 11, by sandwiching the sheets 10 and ii between an ultrasonically vibrated horn (sometimes called a sonotrode) that in the present invention is formed by the tool 16, and an anvil the machine. The reflection of the vibrations of the horn 16 in the weld zone, and the friction of the surfaces of the materials cause the weld region to become heated and the sheets 10 and 11 fuse together. The vibrations are introduced vertically by the tool 16, and the inclined surface 18 of the tool 16 causes frictional heat to be produced so that the sheets 10 and 11 plasticize locally, and forge an insoluble connection between both sheets 10 and 11 within a very short period of time. The prerequisite is that both sheets 10 and 11 have a near equivalent melting point. The joint quality is very uniform because the energy transfer and the released internal heat remains constant and is limited to the joining area. In order to obtain an optimum result, the joining areas of the sheets may be prepared to make them suitable for ultrasonic bonding if desired. Once the two sheets 10 and 11 are ultrasonically welded the top sheet 11 is unfolded about the weld line to produce a unitary article that is butt welded along the weld line.
It is to be understood that the weld line of the finished product may extend perpendicular to the side edges of the product, or at an angle to the side edges. The final product may have its side edges of both sheets 10 and 11 in line with each other, or alternatively the weld may extend perpendicular to the side edges of one sheet 10 and along one edge of the other sheet to form a shape similar to the letter "L". By carrying out multiple welds different shapes of final product could be achieved. For example shapes such as the letter "T" or "V" of other shapes of final products.

Claims (16)

  1. CLAIMS1. A method of butt-welding two thermoplastic sheets together comprising the steps of (f) providing two sheets of thermoplastic weldable materials each having a first surface and a second surface; (g) bringing the two sheets of materials together with their first surfaces confronting each other; (h) positioning an edge of the sheets adjacent a predetermined line; contacting the two sheets with a cutting and welding tool that has an inclined welding surface and a cutting edge that extend in a direction along said predetermined line; (i) urging the tool in a direction towards the two sheets to bring the inclined surface into contact with the two sheets and generating heat so as to melt and fuse the sheets together along said line whilst simultaneously cutting through the two sheets; and (j) unfolding the two sheets to form a unitary article having the two sheets butt welded along said line with their first surfaces facing in a common direction.
  2. 2. A method according to claim 1 wherein the step of generating heat is effected by means of a radio frequency welding process and the tool constitutes one electrical conductor of a pair of opposing conductors between which an electromagnetic field is generated.
  3. 3. A method according to claim 1 wherein the tool constitutes a horn of an ultrasonic welding machine, the sheets to be welded are positioned between the horn and an anvil of the machine, and the step of generating heat is effected by means of an ultrasonic energy welding process.
  4. 4. A method according to any one of the preceding claims wherein the first face of the sheets constitute a front face of the welded article and the second surfaces of the sheets constitute a back face of the welded article.
  5. 5. A cutting and welding tool for carrying out step (c) of the method of any one of claims 1 to 6 wherein the inclined surface of the tool extends in a direction away from the cutting edge at an angle 0 relative to a second surface of the tool that extends in a direction substantially perpendicular from the cutting edge.
  6. 6. A cutting tool according to claim 7 wherein the cutting edge of the tool is in the range of 0.05mm (50j.i) to 0.15mm (lSOp) wide.
  7. 7. A cutting tool according to claim 6 wherein the cutting edge of 5he tool is up to 0.05 mm (50t) wide.
  8. 8. A tool according to any one of claims 5 to 7 wherein the combined thickness (t) of the two sheets when in the position in step (b) of the method of claim I is in the range of 2.0 mm to 1.0 mm, and the angle 0 is in the range of 25 ° to 30°.
  9. 9. A tool according to any one of claims 5 to 7 wherein the combined thickness (t) of the two sheets is in the range of 1.0mm to 0.5mm and the angle 0 is in the range of 300 to 450*
  10. 10. A tool according to any one of claims 5 to 7 wherein the thickness of the two sheets in the range of 0.5mm to 0.1mm and the angle 0 is in the range of 45° to 60°.
  11. 11. A tool according to claim 8 wherein the angle 0 is 30°.
  12. 12. A tool according to claim 9 wherein the angle 0 is 45°.
  13. 13. A tool according to claim 10 wherein the angle 0 is 600.
  14. 14. A welded product wherein the weld is made by the method according to any one of claims 1 to 6.
  15. 15. A welded product according to claim 15 wherein the weld is made by a tool according to any one of claims 7 to 14.
  16. 16. Welding apparatus incorporating a tool constructed according to any one of claims 7 to 13.
GB0921253A 2009-12-04 2009-12-04 Method of welding sheet material Withdrawn GB2475886A (en)

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102615825A (en) * 2012-04-18 2012-08-01 南昌航天文体用品有限公司 Ultrasonic bonding method for J-shaped ruler
US10513079B2 (en) 2016-10-20 2019-12-24 Baxter International Inc. Sealing die with chamfered edge

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1094823A (en) * 1965-03-22 1967-12-13 Uniroyal Inc Joining thermoplastic sheets
US3901749A (en) * 1974-08-27 1975-08-26 Ncr Co Method and apparatus for forming an endless ribbon

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1094823A (en) * 1965-03-22 1967-12-13 Uniroyal Inc Joining thermoplastic sheets
US3901749A (en) * 1974-08-27 1975-08-26 Ncr Co Method and apparatus for forming an endless ribbon

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102615825A (en) * 2012-04-18 2012-08-01 南昌航天文体用品有限公司 Ultrasonic bonding method for J-shaped ruler
US10513079B2 (en) 2016-10-20 2019-12-24 Baxter International Inc. Sealing die with chamfered edge

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