US3401248A - Dielectric die - Google Patents
Dielectric die Download PDFInfo
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- US3401248A US3401248A US498713A US49871365A US3401248A US 3401248 A US3401248 A US 3401248A US 498713 A US498713 A US 498713A US 49871365 A US49871365 A US 49871365A US 3401248 A US3401248 A US 3401248A
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- 239000003989 dielectric material Substances 0.000 abstract description 26
- 238000010438 heat treatment Methods 0.000 abstract description 12
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 abstract description 7
- 229910052802 copper Inorganic materials 0.000 abstract description 7
- 239000010949 copper Substances 0.000 abstract description 7
- 229920001169 thermoplastic Polymers 0.000 abstract description 5
- 239000004416 thermosoftening plastic Substances 0.000 abstract description 5
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 abstract description 5
- 229920002554 vinyl polymer Polymers 0.000 abstract description 5
- 229910001369 Brass Inorganic materials 0.000 abstract description 4
- 229910045601 alloy Inorganic materials 0.000 abstract description 4
- 239000000956 alloy Substances 0.000 abstract description 4
- 239000010951 brass Substances 0.000 abstract description 4
- 125000006850 spacer group Chemical group 0.000 abstract description 4
- 229920000297 Rayon Polymers 0.000 abstract description 2
- 229910052782 aluminium Inorganic materials 0.000 abstract description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 abstract description 2
- 229920002635 polyurethane Polymers 0.000 abstract description 2
- 239000004814 polyurethane Substances 0.000 abstract description 2
- 239000004800 polyvinyl chloride Substances 0.000 abstract description 2
- 229920000915 polyvinyl chloride Polymers 0.000 abstract description 2
- 239000010935 stainless steel Substances 0.000 abstract description 2
- 229910001220 stainless steel Inorganic materials 0.000 abstract description 2
- 229920005992 thermoplastic resin Polymers 0.000 abstract description 2
- 239000002023 wood Substances 0.000 abstract description 2
- 239000004411 aluminium Substances 0.000 abstract 1
- 239000002964 rayon Substances 0.000 abstract 1
- 239000004020 conductor Substances 0.000 description 17
- 239000002184 metal Substances 0.000 description 14
- 229910052751 metal Inorganic materials 0.000 description 14
- 230000003534 oscillatory effect Effects 0.000 description 10
- 239000000463 material Substances 0.000 description 9
- 238000000034 method Methods 0.000 description 8
- 238000004049 embossing Methods 0.000 description 4
- 229920005989 resin Polymers 0.000 description 4
- 239000011347 resin Substances 0.000 description 4
- 238000003475 lamination Methods 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 150000002739 metals Chemical class 0.000 description 3
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 239000012777 electrically insulating material Substances 0.000 description 1
- 229920002457 flexible plastic Polymers 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 235000013305 food Nutrition 0.000 description 1
- 229910001026 inconel Inorganic materials 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000012260 resinous material Substances 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- 239000000057 synthetic resin Substances 0.000 description 1
- 239000012815 thermoplastic material Substances 0.000 description 1
Images
Classifications
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- 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
- 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
- B29C66/45—Joining of substantially the whole surface of the 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
- B29C66/40—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
- B29C66/472—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially 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
- B29C66/80—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
- B29C66/8122—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 composition 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
- B29C66/8126—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 intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
- B29C66/81262—Electrical and dielectric properties, e.g. electrical conductivity
-
- 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
- B29C66/8145—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
- B29C66/81463—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 plurality of single pressing elements, e.g. a plurality of sonotrodes, or comprising a plurality of single counter-pressing elements, e.g. a plurality of anvils, said plurality of said single elements being suitable for making a single 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
- B29C66/80—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
- B29C66/8324—Joining or pressing tools pivoting around one axis
-
- 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
- B29C66/90—Measuring or controlling the joining process
- B29C66/92—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools
- B29C66/929—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges
-
- 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
- B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
-
- 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
- B29C66/73—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
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- 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
- B29C66/90—Measuring or controlling the joining process
- B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
- B29C66/914—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
- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3005—Body finishings
- B29L2031/3014—Door linings
Definitions
- ABSTRACT or THE DISCLOSURE A method and a device for bonding dielectric materials are disclosed. Each is characterized by the utilization of electrodes of varying size and inversely varying electrical resistivity to provide controlled heating.
- This invention is concerned with the field ofdielectric heating and is particularly directed to a method of and means for sealing, embossing, and/or scoring super-imposed sheets of flexible plastic material by meansof high frequency currents and pressure. More particularly, this invention relates to an improved electrode die capable of producing varying amounts of heat at spaced apart locations within a dielectric lamination from a single source, power input.
- thermoplastics include a Ivast number of commercially available materials which are useful in the fabrication of upholstery,' fabrication of waterproof coverings, air-tight enclosures and packages for the shipment of foods, chemicals or other materials which deteriorate in the presence of air or moisture.
- Dielectric heating is a selective heating process whereby heat can be developed within an electrically insulating or dielectric material from the frictional heating caused by molecular rotation within the dielectric by an alternating current of radio frequency.
- the instant die has general utility wherever trim materials are employed including, but not by way of limitation, the production of interior trim for automotive vehicles.
- trim sheets or panels having decorative designs Such panels decorative ice conventionally include a trim material, e.g. one or v,more vinyl sheet materials, positioned on a fibrous or foam pad which is made of or 4impregnated with a heat fusible resinous material and is supported on a iberboard.
- a trim material e.g. one or v,more vinyl sheet materials
- a fibrous or foam pad which is made of or 4impregnated with a heat fusible resinous material and is supported on a iberboard.
- an embossed pattern is produced wherein the trim-material is bonded to the backing through the pad, the resin in the pad along the embossed lines having been melted andcured, thus serving as a bonding adhesive.
- the dielectric dies are constructed according to a given soft trim component design such 4as a door panel or seat bolster. These individual designs require that a die have many different types of bondingl bars or design electrodes in their construction. As the areas to be bonded increases, the amount of power required to produce .the heat necessary for satisfactory bonding also increases;
- FIGURE l is a perspective view of an upholstered door panel for an automobile illustrating an embossed design made in accordance with this invention and indicating areas of bonding to be effected using the die illustrated in the succeeding figures;
- FIGUR-E 2 is a perspective view of a die assembly in accordance with this invention.
- FIGURE 3 is a cross-sectional view taken along line 3 3 of FIGURE 2.
- FIG- URE la door panel 10 upon which three separate em'- bossed areas 13, 15 and 17 indicate three areas of dielectric bonding hereinafter further described in relation to FIGURES 2 and 3.
- a portion of door panel 10 is shown in cross section in FIGURE 3 priorto Ibonding and comprises a pressed wood board 21, a pad 23- comprising viscose bers and a suitable thermoplastic resin, a first thermoplastic vinyl sheet 25, e.g. polyvinylchloride, and a second thermoplastic vinyl sheet 27 which may be of the same chemical composition as sheet 25.
- a die assembly 30 comprising an upper platen electrode 31, lower platen electrode 33, hinge means 35, stop means 37 for holding the die open for loading, clamping means 39 and 41 for holding the panel components in place, bonding design electrodes 43, 45 and 47, and polyurethane spacer pads 49, 51, 53 and 55.
- the spacer pads are removed from areas 61 and 63 to better show the bonding design electrodes.
- electrodes 31 and 33 are aluminum, electrode 43 is copper, electrode 45 is brass, stainless steel, inconel or other suitable alloy and electrode 47 is copper or a suitable alloy.
- electrode 47 has the same electrical resistivity as electrode 43 and electrode 45 has a greater resistivity.
- electrode 47 has a greater electrical resistivity than electrode 43 but a lesser electrical resistivity than electrode 45. Electrodes 43, 45 and 47 are all in electrical connection with electrode 33.
- Electrodes 31 and 33 are electrically connected to a high frequency oscillator 73 or other means for providing a high frequency alternating electric current via conductors 71 and 75 respectively.
- Oscillator 73 is, of course, connected to a suitable electric power source, not shown.
- the oscillatory has been connected with a 44o-volt AC circuit through conventional conversion devices such as rectifers, transformers, etc., to provide aV direct current to the oscillator -at about 12,000 D C. volts. This is then converted by the oscillator to about 5,000 R.F. (radio frequency) volts at about 10 to about 30 megacycles per second.
- R.F. radio frequency
- the components of panel are placed in the indicated order over the design electrodes 43, 45 and 47 and spacer pads 49, 51, 53 and 55 and held in position by clamping means 39 and 41 while electrode 31 is held in open position by stop means 37.
- Stop means 37 is removed or disengaged permitting electrode 31 to close over the clamped panel components and pressure is applied by pressure means, not shown, so as to force electrodes 31 and 33 closer together.
- the requisite pressure for bonding and/or embossing is thus provided, e.g. 200-300 pounds per each square inch of bonding area. In practice this will ordinarily be effected by pneumatic or hydraulic means.
- a high frequency alternating current is applied through the aforedescribed circuit to the electrodes 31, 33, 43, 45 and 47 with resultant heating and bonding of the thermoplastic materials in the areas directly between the design electrodes 43, 45 and 47 and the platen electrode 31.
- the amount of heat required at a given site is controlled in a single circuit by varying the electrical resistivity of the design electrodes which are electrically connected in parallel in accordance with their mass and/or work face area.
- the electrodes 43, 45 and 47 each have a working face 43-1, 454 and 47-1 which is brought into contact with at least one of the dielectric components of the panel, or other workpiece, when the ldie is in use.
- the heating properties of at least two such electrodes are controlled in relation to each other by varying their electrical resistivities inversely with their work face areas. This is effected through a proper choice of electrode metals.
- a die suitable for bonding together dielectric materials comprising a first conductor for electrical connection with a source of high frequency oscillatory energy, a second conductor for electrical connection with said source of energy, a first die member including a platen electrode electrically connected to said first conductor, a second die member including a plurality of bonding design electrodes spaced apart and electrically connected in parallel by said second conductor, said design electrodes each having a work face, and means for urging together said first die member and said second die member when said dielectric materials are sandwiched therebetween in a manner'such as'to bring the work faces of said design electrodes into contact withat least one of said dielectric materials, said design electrodes including a first design electrode having a work face of predetermined area and formed of metal having a predetermined electrical resistivity'l and a seconddesign electrode having awork face of significantly lesser area than said predetermined area and'formed of metal having an electrical resistivity significantly greater than said predetermined electrical resistivity.
- a die suitable for bonding together dielectric materials at least one of which includes a heat softenable resin, comprising a first conductor for electrical connection with a source of high frequency oscillatory energy, a second conductor for electrical connection with said source of energy, a first die member including a platen electrode electrically connected to said first conductor, a second die member including a second platen ⁇ supporting a plurality of bonding design electrodes spaced apart and electrically connected in parallel by said second conductor, said design electrodes each having a work face, and means for urging together said first die member and said second die member when said dielectric materials are sandwiched therebetween in a manner such as to bring the work faces of said design electrodes into contact with at least one of said dielectric materials, said design electrodes including a first design electrode having a work face of predeter-4 mined area and formed of metal having a predetermined electrical resistivity and a second design electrode having a work face of significantly lesser area than said predetermined area and formed of metal having an electrical resistivity significantly greater than said
- a die suitable for embossing and bonding together dielectric materials at least one of which includes a heat softenable resin comprising a first conductor for electrical connection with a source of high frequency oscillatory energy, a second conductor for electrical connection with said source of energy, a ⁇ first die member including a platen electrode electrically connected to said first conductor, -a second die member including a second platen electrode electrically connected to said second conductor, a plurality of bonding design electrodes spaced apart, mounted on, supported by, land electrically connected in parallel by said second platen electrode, said design electrodes each having a work face, and means for urging together said first die member and said second die member when said dielectric materials are sandwiched therebetween in a manner such as to bring the work faces of said design electrodes into contact with lat least one 0f said heat softenable materials, said design electrodes including a first design electrode having a work face of predetermined area and formed of metal having a predetermined electrical resistivity and a second design electrode having a work face
- a die suitable for bonding together dielectric materials comprising a rst conductor for electrical connection with a source of high frequency oscillatory energy, a second conductor for electrical connection with said source of energy, a first die member including a platen electrode electrically connected to said first conductor, -a second die member including a plurality of bonding design electrodes spaced apart and electrically connected in parallel by said second conductor, said design electrodes each having a work face, and means for urging together said first die member and said second die member when said dielectric materials are sandwiched therebetween in a manner suchas to bring the work faces of said design electrodes into contact with atleast one of said dielectric materials, said design electrodes including a first design electrode consisting essentially of copper and having a work face of predetermined area, and a second electrode having a work face of signicantly lesser area than said predetermined area and formed of metal having an electrical resistivity significantly greater than copper.
- a die suitable for bonding together dielectric materials comprising a lirst die member, a second die member, and generator means for passing a high frequency alternating current between said members, said first die member comprising a platen electrode electrically connected to said generator means, said second die member comprising a plurality of bonding design electrodes spaced apart, electrically connected in parallel, and electrically connected to said generator means, said design electrodes each having a work face, and power means for urging one of said die members toward the other when said dielectric materials are sandwiched therebetween in a manner such as to bring the work faces of said design electrodes into contact with at least one of said dielectric materials, said design electrodes including a lirst design electrode having a work face of predetermined area and formed of metal having a predetermined electrical resistivity, and a second design electrode having a work face of signicantly lesser area than said predetermined area and formed of rnetal having an electrical resistivity significantly greater than said predetermined electrical resistivity.
- a process for bonding together dielectric materials which comprises positioning said dielectric materials between a platen electrode electrically connected to a source of high frequency oscillatory energy and plurality of spaced apart bonding design electrodes having different work face areas electrically connected in parallel with each other and in series with said platen electrode, applying sutcient pressure to said electrodes to compress said dielectric materials between said platen electrodes and said design electrodes, and dielectrically heating said dielectric materials in the regions directly between said design electrodes and said platen electrode by impressing a high frequency alternating current potential between said platen electrode and said design electrodes, the improvement which comprises controlling the heat generated between said platen electrode and each of said design elect-rodes by varying the electrical resistivity of said design electrodes inversely with the work face areas of the same.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
- Constitution Of High-Frequency Heating (AREA)
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
Abstract
1,130,615. Dielectric heating electrodes. FORD MOTOR CO. Ltd. 24 Aug., 1966 [20 Oct., 1965], No. 37882/66. Heading H5H. [Also in Division B5] A die for bonding together selected areas of sheets 21, 23, 25, 27 of dielectric material comprises an electrode assembly which includes a plurality of electrodes 43, 45, 47 electrically connected in parallel to a source 73 of R.F. current, the electrodes 43, 45, 47 having working surfaces 43-1, 45-1, 47-1 to press the selected areas against another electrode 31 connected to the source 73 to bond the areas by dielectric heating, the electrical conductivity of the electrodes 43, 45, 47 differing from one electrode to another. A door panel 10, Fig. 3, for an automobile comprises a press wood board 21, a pad 23 comprising rayon fibres and a thermoplastic resin, a thermoplastic vinyl sheet 25, e.g. polyvinyl chloride, and a second thermoplastic vinyl sheet 27. The electrodes 43, 45, 47 are electrically connected to a lower electrode 33 which is connected to the source 73. The electrodes 31, 33 are made of aluminium, the electrode 43 of copper, the electrode 45 of brass, stainless steel or another alloy and the electrode 47 of copper or an alloy. In one embodiment, the electrodes 43, 47 have the same electrical resistivity and the electrode 45 has a greater resistivity. In a second embodiment, the electrode 47 has a greater resistivity than the electrode 43 but less than the electrode 45. In operation, the sheets 21, 23, 25, 27 are placed on the electrodes 43, 45, 47 and polyurethane spacer pads 49, 51, 53, 55 and held in position by clamps 39, 41. Stays 37 are disengaged and the electrode 31 is closed to overlie the sheets. The electrodes 31, 33 are forced together by pressure applied pneumatically or hydraulically and then R.F. is supplied to effect bonding.
Description
Sept. l0, 1968 J. c. KIM 3,401,248 j DIELECTRIC DIE Filed Oct.` 20, 1965 HIGH FREQUENCY osclLLAToR FIGB ,3o JOHN u KIM /71 31 43-1 /10 45-1 auf 47-1 i /Nvf/vron 4s 4.a .f1 v4J .s3 .53' ATTORNEYS United States Patent() 3,401,248 v DIELECTRIC DIE John C. Kim, Pontiac, Mich., assignor to Ford Motor Company, Dearborn, Mich., a corporation of Delaware Filed Oct. 20, 1965, Ser. No. 498,713 7 Claims. (Cl.l 219-,10.53)
ABSTRACT or THE DISCLOSURE A method and a device for bonding dielectric materials are disclosed. Each is characterized by the utilization of electrodes of varying size and inversely varying electrical resistivity to provide controlled heating.
Summary of the disclosure Method and apparatus for bonding together dielectric materials by producing varying amounts of heat at spaced apart locations within a dielectric lamination from a single-source, power input, said method comprising sandwiching said dielectric lamination between a platen electrode and a pair of design electrodes and controlling the heat generated |between said platen electrode and said design electrodes by varying the electrical resistivity of said design electrodes inversely with the work face areas of the same, said apparatus'comprising a source of high frequency oscillatory energy, a first die member including a platen electrode in electrical connection with said source, a second die member including `a plurality of bonding design electrodes in electrical connection with said power source, and means for urging said first die member and said second die member together when said dielectric materials are sandwiched therebetween, Said design electrodes including rst'design electrode having a'working face of predetermined area and formed of metal having a predetermined electrical resistivity and a second design electrode having a work face of significantly lesser area than said predetermined area and formed of metal having an electrical resistivity significantly greater than said predetermined electrical resistivity.
This invention is concerned with the field ofdielectric heating and is particularly directed to a method of and means for sealing, embossing, and/or scoring super-imposed sheets of flexible plastic material by meansof high frequency currents and pressure. More particularly, this invention relates to an improved electrode die capable of producing varying amounts of heat at spaced apart locations within a dielectric lamination from a single source, power input.
:It is well known in the art thatl there area number of synthetic resins which become soft in the presence of suiciently high temperature and which may thus be bonded together by the application ofdielectric heating. These materials are generally classed as thermoplastics and include a Ivast number of commercially available materials which are useful in the fabrication of upholstery,' fabrication of waterproof coverings, air-tight enclosures and packages for the shipment of foods, chemicals or other materials which deteriorate in the presence of air or moisture.
Dielectric heating is a selective heating process whereby heat can be developed within an electrically insulating or dielectric material from the frictional heating caused by molecular rotation within the dielectric by an alternating current of radio frequency. i
The instant die has general utility wherever trim materials are employed including, but not by way of limitation, the production of interior trim for automotive vehicles. There is an increasing--demand'to provide trim sheets or panels having decorative designs. Such panels decorative ice conventionally include a trim material, e.g. one or v,more vinyl sheet materials, positioned on a fibrous or foam pad which is made of or 4impregnated with a heat fusible resinous material and is supported on a iberboard. Upon operation of the dielectric press, an embossed pattern is produced wherein the trim-material is bonded to the backing through the pad, the resin in the pad along the embossed lines having been melted andcured, thus serving as a bonding adhesive. In automotive soft trim Ymanufacturing, the dielectric dies are constructed according to a given soft trim component design such 4as a door panel or seat bolster. These individual designs require that a die have many different types of bondingl bars or design electrodes in their construction. As the areas to be bonded increases, the amount of power required to produce .the heat necessary for satisfactory bonding also increases;
In a method and/ or apparatus suitable for use in conjunction With an assembly line, simplicity of `design and operation are advantageous, if not a requirement, as i's adaptability to rapid and frequent modification.
It is one object of this invention to provide an irnproved method and apparatus for fast efficient dielectric heating.
It is another object to provide an improved method and apparatus adapted to meet varying heat requirements within a single die press without increasing power input or employing multiple circuitry by employing bonding design electrodes of varying mass and work face area electrically connected in parallel and formed of different metals, the electrical resistivity of such metals varying inversely with the work face area of the same.
These and other objects and advantages of this invention will be readily apparent from the following detailed description of a preferred embodiment thereof and the accompanying drawings, in which:
FIGURE l is a perspective view of an upholstered door panel for an automobile illustrating an embossed design made in accordance with this invention and indicating areas of bonding to be effected using the die illustrated in the succeeding figures;
FIGUR-E 2 is a perspective view of a die assembly in accordance with this invention; and
FIGURE 3 is a cross-sectional view taken along line 3 3 of FIGURE 2.
Referring now to the drawing, there is shown in FIG- URE la door panel 10 upon which three separate em'- bossed areas 13, 15 and 17 indicate three areas of dielectric bonding hereinafter further described in relation to FIGURES 2 and 3. A portion of door panel 10 is shown in cross section in FIGURE 3 priorto Ibonding and comprises a pressed wood board 21, a pad 23- comprising viscose bers and a suitable thermoplastic resin,a first thermoplastic vinyl sheet 25, e.g. polyvinylchloride, and a second thermoplastic vinyl sheet 27 which may be of the same chemical composition as sheet 25.
Referring now to FIGURES 2 and 3, there is shown a die assembly 30 comprising an upper platen electrode 31, lower platen electrode 33, hinge means 35, stop means 37 for holding the die open for loading, clamping means 39 and 41 for holding the panel components in place, bonding design electrodes 43, 45 and 47, and polyurethane spacer pads 49, 51, 53 and 55. In FIGURE 2 the spacer pads are removed from areas 61 and 63 to better show the bonding design electrodes. In this embodiment, electrodes 31 and 33 are aluminum, electrode 43 is copper, electrode 45 is brass, stainless steel, inconel or other suitable alloy and electrode 47 is copper or a suitable alloy. In one embodiment, electrode 47 has the same electrical resistivity as electrode 43 and electrode 45 has a greater resistivity. In a secondembodiment,
In operation the components of panel are placed in the indicated order over the design electrodes 43, 45 and 47 and spacer pads 49, 51, 53 and 55 and held in position by clamping means 39 and 41 while electrode 31 is held in open position by stop means 37. Stop means 37 is removed or disengaged permitting electrode 31 to close over the clamped panel components and pressure is applied by pressure means, not shown, so as to force electrodes 31 and 33 closer together. The requisite pressure for bonding and/or embossing is thus provided, e.g. 200-300 pounds per each square inch of bonding area. In practice this will ordinarily be effected by pneumatic or hydraulic means. When the panel components are under the desired pressure, a high frequency alternating current is applied through the aforedescribed circuit to the electrodes 31, 33, 43, 45 and 47 with resultant heating and bonding of the thermoplastic materials in the areas directly between the design electrodes 43, 45 and 47 and the platen electrode 31.
In the dies of this invention, the amount of heat required at a given site is controlled in a single circuit by varying the electrical resistivity of the design electrodes which are electrically connected in parallel in accordance with their mass and/or work face area. The electrodes 43, 45 and 47 each have a working face 43-1, 454 and 47-1 which is brought into contact with at least one of the dielectric components of the panel, or other workpiece, when the ldie is in use. Within a group of design electrodes, thus electrically connected, the heating properties of at least two such electrodes are controlled in relation to each other by varying their electrical resistivities inversely with their work face areas. This is effected through a proper choice of electrode metals. Thus, when a uniform amount of power is applied to the die circuit, those areas requiring predetermined amounts of heat receive the requisite amount from electrodes in the same circuit.
Although the detailed description has been primarily confined to a particular embodiment, it will be understood that other embodiments and modifications may be used within the scope of the invention as set forth in the appended claims.
Iclaim:
1. A die suitable for bonding together dielectric materials comprising a first conductor for electrical connection with a source of high frequency oscillatory energy, a second conductor for electrical connection with said source of energy, a first die member including a platen electrode electrically connected to said first conductor, a second die member including a plurality of bonding design electrodes spaced apart and electrically connected in parallel by said second conductor, said design electrodes each having a work face, and means for urging together said first die member and said second die member when said dielectric materials are sandwiched therebetween in a manner'such as'to bring the work faces of said design electrodes into contact withat least one of said dielectric materials, said design electrodes including a first design electrode having a work face of predetermined area and formed of metal having a predetermined electrical resistivity'l and a seconddesign electrode having awork face of significantly lesser area than said predetermined area and'formed of metal having an electrical resistivity significantly greater than said predetermined electrical resistivity.
2. A die suitable for bonding together dielectric materials, at least one of which includes a heat softenable resin, comprising a first conductor for electrical connection with a source of high frequency oscillatory energy, a second conductor for electrical connection with said source of energy, a first die member including a platen electrode electrically connected to said first conductor, a second die member including a second platen `supporting a plurality of bonding design electrodes spaced apart and electrically connected in parallel by said second conductor, said design electrodes each having a work face, and means for urging together said first die member and said second die member when said dielectric materials are sandwiched therebetween in a manner such as to bring the work faces of said design electrodes into contact with at least one of said dielectric materials, said design electrodes including a first design electrode having a work face of predeter-4 mined area and formed of metal having a predetermined electrical resistivity and a second design electrode having a work face of significantly lesser area than said predetermined area and formed of metal having an electrical resistivity significantly greater than said predetermined electric al resistivity.
3. A die suitable for embossing and bonding together dielectric materials at least one of which includes a heat softenable resin comprising a first conductor for electrical connection with a source of high frequency oscillatory energy, a second conductor for electrical connection with said source of energy, a `first die member including a platen electrode electrically connected to said first conductor, -a second die member including a second platen electrode electrically connected to said second conductor, a plurality of bonding design electrodes spaced apart, mounted on, supported by, land electrically connected in parallel by said second platen electrode, said design electrodes each having a work face, and means for urging together said first die member and said second die member when said dielectric materials are sandwiched therebetween in a manner such as to bring the work faces of said design electrodes into contact with lat least one 0f said heat softenable materials, said design electrodes including a first design electrode having a work face of predetermined area and formed of metal having a predetermined electrical resistivity and a second design electrode having a work face of significantly lesser area than said predetermined area and formed of metal having an electrical resistivity significantly greater than said predetermined electrical resistivity.
4. A die suitable for bonding together dielectric materials comprising a rst conductor for electrical connection with a source of high frequency oscillatory energy, a second conductor for electrical connection with said source of energy, a first die member including a platen electrode electrically connected to said first conductor, -a second die member including a plurality of bonding design electrodes spaced apart and electrically connected in parallel by said second conductor, said design electrodes each having a work face, and means for urging together said first die member and said second die member when said dielectric materials are sandwiched therebetween in a manner suchas to bring the work faces of said design electrodes into contact with atleast one of said dielectric materials, said design electrodes including a first design electrode consisting essentially of copper and having a work face of predetermined area, and a second electrode having a work face of signicantly lesser area than said predetermined area and formed of metal having an electrical resistivity significantly greater than copper.
5. A die suitable for bonding together dielectric materials comprising a lirst die member, a second die member, and generator means for passing a high frequency alternating current between said members, said first die member comprising a platen electrode electrically connected to said generator means, said second die member comprising a plurality of bonding design electrodes spaced apart, electrically connected in parallel, and electrically connected to said generator means, said design electrodes each having a work face, and power means for urging one of said die members toward the other when said dielectric materials are sandwiched therebetween in a manner such as to bring the work faces of said design electrodes into contact with at least one of said dielectric materials, said design electrodes including a lirst design electrode having a work face of predetermined area and formed of metal having a predetermined electrical resistivity, and a second design electrode having a work face of signicantly lesser area than said predetermined area and formed of rnetal having an electrical resistivity significantly greater than said predetermined electrical resistivity.
6. A die suitable for embossing and bonding together dielectric materials at least one which includes a heat softenable resin comprising a rst die member, a second die member, and oscillatory means for passing a radio frequency alternating current between said members, said lrst die member comprising a platen electrode electrically connected to said oscillatory means, said second die member comprising an electrode support member supporting a plurality of bonding design electrodes spaced apart, electrically connected in parallel, and electrically connected to said oscillatory means, said design electrodes each having `a work face, and power means for urging one of said die members toward the other when said dielectric materials are sandwiched therebetween in a manner such as to bring the Work faces of said design electrodes into Contact with at least one of said dielectric materials, said design electrodes including a lirst design electrode having a work face of predetermined area and consisting essentially of copper, a second design electrode having a work face of significantly lesser area thanl said predetermined area and consisting essentially of brass, and a third design electrode having a work face of signicantly lesser area than the work face of said second design electrode and formed of a metal having an electrical resistivity signilicantliy greater than the brass of said second electrode.
7. In a process for bonding together dielectric materials which comprises positioning said dielectric materials between a platen electrode electrically connected to a source of high frequency oscillatory energy and plurality of spaced apart bonding design electrodes having different work face areas electrically connected in parallel with each other and in series with said platen electrode, applying sutcient pressure to said electrodes to compress said dielectric materials between said platen electrodes and said design electrodes, and dielectrically heating said dielectric materials in the regions directly between said design electrodes and said platen electrode by impressing a high frequency alternating current potential between said platen electrode and said design electrodes, the improvement which comprises controlling the heat generated between said platen electrode and each of said design elect-rodes by varying the electrical resistivity of said design electrodes inversely with the work face areas of the same.
References Cited UNITED STATES PATENTS 7/1962 Beck et al 156-273 X 9/1962 Spieles 2l9-l0.53
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US498713A US3401248A (en) | 1965-10-20 | 1965-10-20 | Dielectric die |
GB37882/66A GB1130615A (en) | 1965-10-20 | 1966-08-24 | Dies for bonding dielectric materials |
DE1966F0050097 DE1604534B1 (en) | 1965-10-20 | 1966-09-01 | Device for joining and embossing dielectric materials |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US498713A US3401248A (en) | 1965-10-20 | 1965-10-20 | Dielectric die |
Publications (1)
Publication Number | Publication Date |
---|---|
US3401248A true US3401248A (en) | 1968-09-10 |
Family
ID=23982188
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US498713A Expired - Lifetime US3401248A (en) | 1965-10-20 | 1965-10-20 | Dielectric die |
Country Status (3)
Country | Link |
---|---|
US (1) | US3401248A (en) |
DE (1) | DE1604534B1 (en) |
GB (1) | GB1130615A (en) |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3740512A (en) * | 1971-12-06 | 1973-06-19 | Dab Ind Inc | Method for adhering friction material to ring-like element |
US3742180A (en) * | 1971-05-26 | 1973-06-26 | Usm Corp | High frequency cavity press |
US3876486A (en) * | 1973-12-06 | 1975-04-08 | William Pennington | Heat sealing of plastic sheets |
US4771150A (en) * | 1987-06-29 | 1988-09-13 | Tachi-S Co., Ltd. | Method of forming trim cover assembly for automotive seat |
US5488221A (en) * | 1995-01-18 | 1996-01-30 | Amabile; Louis | Slot interlock connectors for RF welding electrodes |
US6559432B1 (en) * | 2000-08-03 | 2003-05-06 | Casco Products, Inc. | Apparatus and methods for welding flexible material |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4251310A (en) * | 1977-11-25 | 1981-02-17 | Baxter Travenol Laboratories, Inc. | Method for rebonding tubing elements used in needle assemblies |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3047451A (en) * | 1959-12-28 | 1962-07-31 | Gen Motors Corp | Dielectric embossing process and apparatus |
US3053960A (en) * | 1958-11-26 | 1962-09-11 | Gen Motors Corp | Dielectric process and apparatus for forming materials |
Family Cites Families (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2822454A (en) * | 1956-06-14 | 1958-02-04 | Radio Receptor Company Inc | Heat sealing apparatus |
-
1965
- 1965-10-20 US US498713A patent/US3401248A/en not_active Expired - Lifetime
-
1966
- 1966-08-24 GB GB37882/66A patent/GB1130615A/en not_active Expired
- 1966-09-01 DE DE1966F0050097 patent/DE1604534B1/en active Pending
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3053960A (en) * | 1958-11-26 | 1962-09-11 | Gen Motors Corp | Dielectric process and apparatus for forming materials |
US3047451A (en) * | 1959-12-28 | 1962-07-31 | Gen Motors Corp | Dielectric embossing process and apparatus |
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3742180A (en) * | 1971-05-26 | 1973-06-26 | Usm Corp | High frequency cavity press |
US3740512A (en) * | 1971-12-06 | 1973-06-19 | Dab Ind Inc | Method for adhering friction material to ring-like element |
DE2238558A1 (en) * | 1971-12-06 | 1973-06-20 | Dab Ind Inc | METHOD OF BONDING A FRICTION MATERIAL TO A RING-LIKE ELEMENT |
US3876486A (en) * | 1973-12-06 | 1975-04-08 | William Pennington | Heat sealing of plastic sheets |
US4771150A (en) * | 1987-06-29 | 1988-09-13 | Tachi-S Co., Ltd. | Method of forming trim cover assembly for automotive seat |
US5488221A (en) * | 1995-01-18 | 1996-01-30 | Amabile; Louis | Slot interlock connectors for RF welding electrodes |
US6559432B1 (en) * | 2000-08-03 | 2003-05-06 | Casco Products, Inc. | Apparatus and methods for welding flexible material |
Also Published As
Publication number | Publication date |
---|---|
GB1130615A (en) | 1968-10-16 |
DE1604534B1 (en) | 1971-09-16 |
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