WO2011065827A1 - Method and device for connecting a material layer to a plastic object - Google Patents

Method and device for connecting a material layer to a plastic object Download PDF

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Publication number
WO2011065827A1
WO2011065827A1 PCT/NL2010/050794 NL2010050794W WO2011065827A1 WO 2011065827 A1 WO2011065827 A1 WO 2011065827A1 NL 2010050794 W NL2010050794 W NL 2010050794W WO 2011065827 A1 WO2011065827 A1 WO 2011065827A1
Authority
WO
WIPO (PCT)
Prior art keywords
material layer
plastic
plastic object
heat
heat source
Prior art date
Application number
PCT/NL2010/050794
Other languages
French (fr)
Inventor
Hendrik Jan Gerritsen
Henricus Johannes Marinus Ten Brummelhuis
Original Assignee
Statiqcooling B.V.
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Statiqcooling B.V. filed Critical Statiqcooling B.V.
Priority to AU2010325233A priority Critical patent/AU2010325233A1/en
Priority to EP10788415A priority patent/EP2504152A1/en
Publication of WO2011065827A1 publication Critical patent/WO2011065827A1/en

Links

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
    • 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
    • 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
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • 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
    • B29C66/004—Preventing sticking together, e.g. of some areas of the parts to be joined
    • B29C66/0042—Preventing sticking together, e.g. of some areas of the parts to be joined of the joining tool and the parts to be joined
    • B29C66/0044—Preventing sticking together, e.g. of some areas of the parts to be joined of the joining tool and the parts to be joined using a separating sheet, e.g. fixed on the joining tool
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
    • 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
    • B29C66/345—Progressively making the joint, e.g. starting from the middle
    • 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
    • B29C66/70—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
    • B29C66/71—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
    • B29C66/712—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 the composition of one of the parts to be joined being different from the composition 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
    • B29C66/70—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
    • B29C66/729—Textile or other fibrous material made from plastics
    • B29C66/7294—Non woven mats, e.g. felt
    • 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
    • B29C66/7311—Thermal properties
    • B29C66/73115—Melting point
    • 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
    • B29C66/7311—Thermal properties
    • B29C66/73115—Melting point
    • B29C66/73116—Melting point of different melting point, i.e. the melting point of one of the parts to be joined being different from the melting point 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
    • B29C66/70—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
    • B29C66/70—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
    • B29C66/74—Joining plastics material to non-plastics material
    • B29C66/748—Joining plastics material to non-plastics material to natural products or their composites, not provided for in groups B29C66/742 - B29C66/746
    • B29C66/7485—Natural fibres, e.g. wool, cotton
    • 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
    • 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
    • B29C66/82—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps
    • B29C66/822—Transmission mechanisms
    • B29C66/8221—Scissor or lever mechanisms, i.e. involving a pivot point
    • 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
    • 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
    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
    • B29C66/8351—Jaws mounted on rollers, cylinders, drums, bands, belts or chains; Flying jaws
    • B29C66/83541—Jaws mounted on rollers, cylinders, drums, bands, belts or chains; Flying jaws flying jaws, e.g. jaws mounted on crank mechanisms or following a hand over hand movement
    • 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
    • B29C66/836—Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table
    • 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
    • B29C66/912—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux
    • B29C66/9121—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature
    • B29C66/91231—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature of the joining tool
    • 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
    • B29C66/9141—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 temperature
    • B29C66/91421—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 temperature of the joining tools
    • 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
    • B29C66/9141—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 temperature
    • B29C66/91431—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 temperature the temperature being kept constant over time
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0076—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised in that the layers are not bonded on the totality of their surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0076—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised in that the layers are not bonded on the totality of their surfaces
    • B32B37/0084—Point bonding
    • 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
    • B29C66/303—Particular design of joint configurations the joint involving an anchoring effect
    • 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
    • B29C66/72—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
    • B29C66/729—Textile or other fibrous material made from plastics
    • 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
    • B29C66/818—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 cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps
    • B29C66/8181—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 cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the cooling constructional aspects
    • 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
    • B29C66/96—Measuring or controlling the joining process characterised by the method for implementing the controlling of the joining process
    • B29C66/961—Measuring or controlling the joining process characterised by the method for implementing the controlling of the joining process involving a feedback loop mechanism, e.g. comparison with a desired value
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/20—Fibres of continuous length in the form of a non-woven mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/02—Temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/08—Dimensions, e.g. volume
    • B32B2309/10—Dimensions, e.g. volume linear, e.g. length, distance, width
    • B32B2309/105—Thickness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2323/00—Polyalkenes
    • B32B2323/10—Polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2327/00—Polyvinylhalogenides
    • B32B2327/12—Polyvinylhalogenides containing fluorine
    • B32B2327/18—PTFE, i.e. polytetrafluoroethylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2333/00—Polymers of unsaturated acids or derivatives thereof
    • B32B2333/04—Polymers of esters
    • B32B2333/12—Polymers of methacrylic acid esters, e.g. PMMA, i.e. polymethylmethacrylate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2377/00—Polyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method

Definitions

  • the invention relates to a method for realizing a welded connection between a material layer and a plastic object using heat.
  • the invention also relates to a device for realizing a welded connection between a material layer and a plastic object using heat, particularly by applying the method according to the invention.
  • the invention further relates to an assembly of an object manufactured at least partially from plastic and a material layer connected to the object and manufactured using a device according to the invention.
  • the known method moreover has the limitation that the material layer and the plastic sheet must be capable of fusing together, whereby the known method cannot therefore be applied when the material layer takes a non-meltable or hardly meltable form.
  • An object of the invention is to provide an improved method for mutually connecting a material layer and a plastic object by applying heat.
  • the invention provides for this purpose a method according to the type stated in the preamble, comprising of: A) positioning a material layer with a first melting temperature relative to an object manufactured at least partially from plastic with a second melting temperature, B) pressing the material layer against the plastic object at a welding location by means of a heat source, wherein the temperature of the heat source lies between the first melting temperature of the material layer and the second melting temperature of the plastic object, whereby the plastic object will soften at the welding location and adhere to the material layer, C) allowing the plastic object to cure by means of cooling at least at a part of the location, wherein the material layer remains pressed against the plastic object at and/or close to the location, and D) discontinuing the pressure exerted on the material layer and the plastic object at the position of the welding location after curing of the plastic object.
  • the choice of material for the material layer in the method according to the invention is moreover considerably less critical, since in the method according to the invention the operational temperature of the heat source is lower than the (possible) melting temperature of the material layer, whereby the material layer will not soften, or hardly so, during application of the method and therefore remains substantially wholly undamaged physically and chemically. Leaving the material layer substantially wholly intact has significant advantages in determined applications.
  • An example of an application in which application of the method according to the invention results in significant advantage is an indirect static cooler, particularly a dew point cooler, as described in the Netherlands patent NL2000079, in which a hygroscopic cover layer is attached at point locations to a plastic sheet.
  • the object manufactured at least partially f om plastic referred to briefly as the plastic object, as applied in the method according to the invention can be of very diverse nature and can typically be a three-dimensional or a plastic sheet, although it is also possible to envisage the object manufactured at least partially from plastic being formed as such by a substantially flexible (second) material layer, such as a plastic web or a plastic film.
  • the material layer which will be attached as such against the plastic object can also be formed by a film, a web, a knit, or a non-woven.
  • the choice of material for the material layer is less critical in the method according to the invention, wherein the material layer can for instance be manufactured from plastic, metal, paper, glass and/or textile.
  • welding is understood to mean realizing an adhesion between the plastic object and the material layer by softening (only) the plastic object.
  • Melting temperature is understood to mean the lowest temperature at which the material layer or the plastic object will transpose from a solid state to a substantially liquid state, and therefore becomes substantially softer and stickier (tackier).
  • the lower limit of the melting range is then deemed to be the melting point. It is also possible to envisage the material layer not having a melting temperature as such because the material layer can be manufactured from a non-meltable material.
  • the heat source is displaced relative to the material layer during step C), whereby the pressure exerted on the material layer by the heat rod at the position of the welding location is at least partially relieved.
  • a displacement of the heat rod relative to the material layer is aimed at continuing to press the material layer against the plastic object, wherein at least a part of the welding location is no longer under pressure, whereby cooling and therefore curing of the softened plastic can occur there. This is because removal of the heat source from the material layer while the plastic at the position of the welding location has not yet solidified (cured) would generally result in the heat source pulling the material layer off the plastic object, whereby no welded connection would be realized, or the welded connection could be broken.
  • the contact surface between the heat source and the material layer is made smaller during step C), whereby at least a part of the welding location is left clear and can thus cool.
  • This reduction in the size of the contact surface can for instance be realized by tilting the heat source relative to the material layer, whereby the heat source rotates on the material layer.
  • the welding location will be determined by the positioning of the heat source relative to the material layer. With displacement of the heat source relative to the material layer a larger welded connection can generally be obtained.
  • the contact surface between the heat source and the material layer need not necessarily be made smaller here.
  • step E) comprising of positioning a (heat-resistant) protective layer on a side of the material layer remote from the plastic object after positioning of the material layer relative to the plastic object as according to step A), wherein during step B) the heat source exerts pressure on the material layer via the protective layer.
  • a (heat-resistant) protective layer is a film manufactured from Teflon®
  • PTFE polytetrafluoroethylene
  • the method comprises step F), comprising of pressing the material layer against the plastic object at a distance close to the welding location with at least one retaining element.
  • this at least one retaining element forms a separate element adjacently of the heat source and makes it possible to remove the heat source from the material layer after softening of the plastic by the heat source without the material layer being pulled loose from the plastic object. It is advantageous for this purpose for the heat source to be removed from the material layer after performing step B), wherein the material layer remains pressed against the plastic object by means of the at least one retaining element as according to step F).
  • the at least one retaining element can be removed from the material layer after curing of the plastic object at the position of the welding location as according to step C).
  • the material layer predefined manner. It is generally advantageous for the material layer to be positioned in tensioned state relative to the plastic object during step A).
  • the tensioned state prevents creases forming in the material layer, whereby the material layer can generally be better attached against the plastic object in predefined manner.
  • Steps A)-D) will generally be repeated at different welding locations on the material layer, whereby a spot weld pattern and/or line weld pattern will in fact be generated and whereby a strong, reliable and durable attachment of the material layer against the plastic object can be effected in relatively simple manner.
  • the temperature of the heat source lies between 230 °C and 245 °C during step B).
  • a sheet manufactured from polypropylene with a melting point of 230 °C is usually applied as plastic object, and a non-woven material layer manufactured from polyester and/or polyamide (nylon) is applied as material layer.
  • Polyester has a melting temperature of 245° C and polyamide has a melting temperature of 250 °C. Heating the heat source to a temperature within said temperature range can achieve that only the plastic sheet will melt position- selectively and that the material layer will remain in solid state. It is possible to envisage using other thermoplastic polymers instead of polypropylene.
  • the invention also relates to a device for realizing a welded connection between a material layer and a plastic object using heat, particularly for application of the method according to the invention, comprising: a support structure for supporting an assembly of an object manufactured at least partially from plastic, and a material layer, at least one heat source positioned displaceably relative to the support structure for pressing the material layer against the plastic object at a welding location in order to soften the plastic object at the welding location, and thereby adhere the plastic object to the material layer, and at least one retaining element for pressing the material layer against the plastic object at a part of the welding location or close to the welding location to allow the plastic object to cure at least at a part of the welding location.
  • At least one heat source is formed by a blunt heat rod.
  • the bluntness of the heat rod prevents the heat rod penetrating or at least damaging the material layer.
  • the term heat rod does however generally imply the presence of a contact surface of a limited size.
  • the heat rod can also be used by a hollow pin, using which a round or double-round (concentric) weld impression can be formed.
  • the shaping of the contact surface of the heat rod can be diverse and can for instance be round, oval, triangular, square or rectangular.
  • the heat rod can be connected pivotally to the support structure to allow rotating of the heat rod on the material layer, whereby on the one hand the welding location can at least partially cool while on the other the heat rod continues to exert sufficient pressure on the material layer until the melted plastic has solidified sufficiently.
  • the heat source and the retaining element take an integrated form.
  • the heat rod and the at least one retaining element are embodied as separate elements, wherein the at least one retaining element is for instance formed by a retaining foot adapted to press the material layer against the plastic object a short distance from the welding location. After causing position-selective melting of the plastic the heat rod can be removed from the material layer, wherein the retaining foot continues to exert pressure on the material layer until the plastic has cooled sufficiently.
  • At least one heat source is formed by a displaceable heat carriage adapted to slide over the material layer. Causing the heat carriage to slide over the material layer creates the situation where a welding location is first placed under pressure by the heat carriage, after which the heat carriage slides away from this welding location, whereby the welding location can cool and mutual adhesion of the material layer to the plastic object will occur. Because the heat carriage slides away from the above stated welding location, the heat carriage continues to exert pressure on the material layer in the direction of the plastic object, this generally enhancing the mutual adhesion between the material layer and the plastic object. It is generally advantageous to apply a protective layer between the heat carriage and the material layer which facilitates the sliding of the heat carriage and thereby prevents damage to the material layer.
  • the device comprises at least one holder for holding a protective layer such that the at least one heat source can exert pressure on the material layer via the protective layer.
  • the result of attaching the material layer to the plastic object using the heat carriage is generally a line weld connection.
  • the support structure is generally adapted to support the assembly of the plastic object and the material layer such that the material layer is supported by the plastic object.
  • a contact surface of the plastic object will usually have a substantially horizontal orientation here, whereby the material layer can be supported.
  • This embodiment is in general particularly advantageous from a logistical and structural viewpoint.
  • the device comprises tensioning means for tensioning the material layer relative to the plastic object, whereby the material layer can be attached against the plastic object relatively smoothly and in predefined manner.
  • the device comprises a control unit for controlling the device as defined in the method according to the invention. It is generally advantageous here for the heat rod to comprise at least one temperature sensor, which temperature sensor is connected to the control unit. The temperature of the heat rod can in this way be monitored and regulated in order to have the operational temperature of the heat rod reach a temperature between the melting temperature of the plastic object, or at least of the contact surface of the plastic object, and the melting temperature of the material layer.
  • the invention further relates to an assembly of an object manufactured at least partially from plastic and a material layer connected to the object by means of one or more welded connections and manufactured using a device according to the invention.
  • a characteristic of the assembly is that the material layer is not (noticeably) damaged at the position of the welding location.
  • figures la- Id show a schematic view of successive method steps for realizing a welded connection between a plastic sheet and a material layer according to the invention by making use of a device according to the invention
  • FIGS. 2a-2e show a schematic view of alternative successive method steps for realizing a welded connection between a plastic sheet and a material layer according to the invention by making use of another device according to the invention
  • figure 3 shows a schematic view of yet another device for realizing a welded connection between a plastic sheet and a material layer according to the invention
  • FIGS. 4a-4e show a schematic view of other successive method steps for realizing a welded connection between a plastic sheet and a material layer according to the invention by making use of another device according to the invention.
  • Figures la- Id show a schematic view of successive method steps for realizing a welded connection between a plastic sheet 1 and a material layer 2 according to the invention by making use of a device 3 according to the invention.
  • Plastic sheet 1 is supported here by a displaceable support structure 4 of device 1, and material layer 2 is supported by plastic sheet 1.
  • Plastic sheet 1 is manufactured from polypropylene and in this exemplary embodiment has a thickness of 10 millimetres.
  • Material layer 2 is a non- woven manufactured from both polyamide and polyester, and in this exemplary embodiment has a thickness of 0.22 millimetres.
  • a blunt heat rod 5 is placed in a correct position above material layer 2.
  • Heat rod 5 here comprises a heat-generating element 6 (shown schematically), as well as a cooling casing 7 to enable an outer side of heat rod 5 to be kept sufficiently cold to make durable mechanical displacement in a bearing unit (not shown) possible.
  • the operational temperature of the core of heat rod 5 lies between the melting temperature of the plastic sheet, in this case 230°C, and the melting temperature of material layer 2, in this case about 245°C.
  • heat rod 5 is moved in downward direction until a blunt underside 5a of heat rod 5 presses against material layer 2, and as such presses material layer 2 against plastic sheet 1.
  • a blunt underside 5a of heat rod 5 presses against material layer 2, and as such presses material layer 2 against plastic sheet 1.
  • the melted plastic is indicated by means of A.
  • the plastic becomes soft and tacky and will adhere to material layer 2.
  • Heat rod 5 is then tilted (figure lc), whereby heat rod 5 will rotate on material layer 2, wherein the contact surface between heat rod 5 and material layer 2 is made smaller.
  • Figures 2a-2e show a schematic view of alternative successive method steps for realizing a welded connection between a plastic sheet 8 and a material layer 9 according to the invention by making use of another device 10 according to the invention.
  • Device 10 is adapted to realize a line weld connection.
  • Plastic sheet 8 is supported releasably here by a displaceable support structure 11 of device 10, and material layer 9 is supported by plastic sheet 8.
  • Plastic sheet 8 is manufactured from polymethyl methacrylate (PMMA) and in this exemplary embodiment has a thickness of 10 millimetres.
  • Material layer 9 is a web manufactured from polyamide, and in this exemplary embodiment has a thickness of 0.22 millimetres.
  • a first step material layer 9 is tensioned and positioned correctly relative to plastic sheet 8, and a heat-resistant protective layer 12 manufactured from Teflon® is positioned against a side of material layer 9 remote from plastic sheet 8.
  • a heat carriage 13 is also placed in a correct position above material layer 9.
  • Heat carriage 13 comprises here a heating coil 14 (shown schematically). In operating situation the operational temperature of heat carriage 13 lies between the melting temperature of the plastic sheet, in this case 230 °C, and the melting temperature of material layer 9, in this case about 245 °C.
  • a second step heat carriage 13 is moved in downward direction until heat carriage 13 engages under bias on material layer 9 and as such presses material layer 9 against plastic sheet 8.
  • heat carriage 13 is in stationary position and support structure 11, together with plastic sheet 8 and material layer 9, is displaced linearly relative to heat carriage 13.
  • Protective layer 12 is advanced at the same speed as the displacement speed of support structure 11, plastic sheet 8 and material layer 9, wherein protective layer 12 can be formed by an endless conveyor belt.
  • FIG 3 shows a schematic view of yet another device 15 for realizing a welded connection between a plastic sheet 16 and a material layer 17 according to the invention.
  • Device 15 comprises a support structure 18 for supporting plastic sheet 16 and material layer 17 positioned thereon.
  • a heat rod 1 forming part of device 15 a welded connection can be realized by only position-selective melting of plastic sheet 16 as described at length in the foregoing.
  • Device 15 further comprises a displaceabie hollow cylindrical foot 20 in which heat rod 19 is displaceably received.
  • the orientation of material layer 17 relative to plastic sheet 16 can be fixed
  • Figures 4a-4e show a schematic view of other successive method steps for realizing a welded connection between a plastic sheet 21 and a material layer 22 according to the invention by making use of another device 23 according to the invention.
  • Plastic sheet 21 is supported here by a displaceabie support structure 24 of device 23 and material layer 22 is supported by plastic sheet 21.
  • Plastic sheet 21 is manufactured in this exemplary embodiment from polypropylene and has a thickness of 20 millimetres.
  • Material layer 22 is a non- woven manufactured from both polyamide and polyester, and in this exemplary embodiment has a thickness of 0.25 millimetres.
  • material layer 22 is positioned correctly relative to plastic sheet 21 and a pivotally suspended hollow heat rod 25 is placed in an initial tilted position above material layer 22.
  • Heat rod 25 here comprises a heat-generating element 26 (shown schematically) and a cooling casing 27 to enable an outer side of heat rod 25 to be kept sufficiently cold to make durable mechanical displacement in a bearing unit (not shown) possible.
  • the operational temperature of the underside of heat rod 25 lies between the melting temperature of the plastic sheet, in this case 230 °C, and the melting temperature of material layer 22, in this case about 245 °C.
  • heat rod 25 is moved in downward direction until a part of underside 25a of heat rod 25 presses against material layer 22 and as such presses material layer 22 against plastic sheet 21.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

Method for realizing a welded connection between a material layer and a plastic object using heat, comprising of positioning a material layer with a first melting temperature relative to an object manufactured at least partially from plastic with a second melting temperature, pressing the material layer against the plastic object at a welding location by means of a heat source, wherein the temperature of the heat source lies between the first melting temperature of the material layer and the second melting temperature of the plastic object, whereby the plastic object will soften at the welding location and adhere to the material layer, allowing the plastic object to cure by means of cooling at least at a part of the location, wherein the material layer remains pressed against the plastic object at and/or close to the location, and discontinuing the pressure exerted on the material layer and the plastic object at the position of the welding location after curing of the plastic object.

Description

Method and device for connecting a material layer to a plastic object
The invention relates to a method for realizing a welded connection between a material layer and a plastic object using heat. The invention also relates to a device for realizing a welded connection between a material layer and a plastic object using heat, particularly by applying the method according to the invention. The invention further relates to an assembly of an object manufactured at least partially from plastic and a material layer connected to the object and manufactured using a device according to the invention.
It is known to attach a plastic material layer to a plastic object, particularly a plastic sheet, by means of a welded connection. The known method generally makes use here of a thermal sewing machine comprising a heat needle and a foot. The material layer is pressed against the plastic sheet by means of the foot, after which the heated heat needle penetrates both the material layer and the plastic sheet. During this penetration both the material layer and the plastic sheet will melt in position-selective manner, after which they fuse together, thereby realizing a welded connection. An example of this known method is described in US 2,477,040. The penetration, and thereby damaging of both the material layer and the plastic sheet, is however undesirable in determined applications. The known method moreover has the limitation that the material layer and the plastic sheet must be capable of fusing together, whereby the known method cannot therefore be applied when the material layer takes a non-meltable or hardly meltable form. An object of the invention is to provide an improved method for mutually connecting a material layer and a plastic object by applying heat.
The invention provides for this purpose a method according to the type stated in the preamble, comprising of: A) positioning a material layer with a first melting temperature relative to an object manufactured at least partially from plastic with a second melting temperature, B) pressing the material layer against the plastic object at a welding location by means of a heat source, wherein the temperature of the heat source lies between the first melting temperature of the material layer and the second melting temperature of the plastic object, whereby the plastic object will soften at the welding location and adhere to the material layer, C) allowing the plastic object to cure by means of cooling at least at a part of the location, wherein the material layer remains pressed against the plastic object at and/or close to the location, and D) discontinuing the pressure exerted on the material layer and the plastic object at the position of the welding location after curing of the plastic object. By only exerting pressure on the material layer and transmitting heat to the plastic object via the material layer, whereby the plastic object will soften and adhere to the material layer, a connection can be realized between the material layer and the plastic object without having to penetrate and damage the material layer. Because the heat source does not need to penetrate the material layer, an underside of the heat source functioning as heat-transmitting contact surface can be given larger dimensions than a conventional heat needle, whereby welded connections which are of larger dimensions, and therefore stronger, can be realized by applying the method according to the invention. The choice of material for the material layer in the method according to the invention is moreover considerably less critical, since in the method according to the invention the operational temperature of the heat source is lower than the (possible) melting temperature of the material layer, whereby the material layer will not soften, or hardly so, during application of the method and therefore remains substantially wholly undamaged physically and chemically. Leaving the material layer substantially wholly intact has significant advantages in determined applications. An example of an application in which application of the method according to the invention results in significant advantage is an indirect static cooler, particularly a dew point cooler, as described in the Netherlands patent NL2000079, in which a hygroscopic cover layer is attached at point locations to a plastic sheet. Because the cover layer is adapted in this application for substantially vertical liquid transport, leaving the cover layer undamaged is important in preventing any obstruction of the liquid transport through the cover layer as far as possible. The object manufactured at least partially f om plastic, referred to briefly as the plastic object, as applied in the method according to the invention can be of very diverse nature and can typically be a three-dimensional or a plastic sheet, although it is also possible to envisage the object manufactured at least partially from plastic being formed as such by a substantially flexible (second) material layer, such as a plastic web or a plastic film. The material layer which will be attached as such against the plastic object can also be formed by a film, a web, a knit, or a non-woven. As already indicated, the choice of material for the material layer is less critical in the method according to the invention, wherein the material layer can for instance be manufactured from plastic, metal, paper, glass and/or textile. The terms welding, welded connection and welding location must be interpreted in a relatively broad sense in the context of this patent publication, wherein in this context welding is understood to mean realizing an adhesion between the plastic object and the material layer by softening (only) the plastic object. Melting temperature is understood to mean the lowest temperature at which the material layer or the plastic object will transpose from a solid state to a substantially liquid state, and therefore becomes substantially softer and stickier (tackier). In the case a melting range is applicable to the material layer or the plastic object, the lower limit of the melting range is then deemed to be the melting point. It is also possible to envisage the material layer not having a melting temperature as such because the material layer can be manufactured from a non-meltable material.
In an embodiment the heat source is displaced relative to the material layer during step C), whereby the pressure exerted on the material layer by the heat rod at the position of the welding location is at least partially relieved. Such a displacement of the heat rod relative to the material layer is aimed at continuing to press the material layer against the plastic object, wherein at least a part of the welding location is no longer under pressure, whereby cooling and therefore curing of the softened plastic can occur there. This is because removal of the heat source from the material layer while the plastic at the position of the welding location has not yet solidified (cured) would generally result in the heat source pulling the material layer off the plastic object, whereby no welded connection would be realized, or the welded connection could be broken. In a particular embodiment the contact surface between the heat source and the material layer is made smaller during step C), whereby at least a part of the welding location is left clear and can thus cool. This reduction in the size of the contact surface can for instance be realized by tilting the heat source relative to the material layer, whereby the heat source rotates on the material layer. As long as the heat source remains at a sufficient temperature, the welding location will be determined by the positioning of the heat source relative to the material layer. With displacement of the heat source relative to the material layer a larger welded connection can generally be obtained. The contact surface between the heat source and the material layer need not necessarily be made smaller here. The displacement of the heat source relative to the material layer during step C) can after all also take place by allowing the heat source to slide over the material layer, whereby a line weld connection can be realized. In a particular embodiment of the method according to the invention the method comprises step E), comprising of positioning a (heat-resistant) protective layer on a side of the material layer remote from the plastic object after positioning of the material layer relative to the plastic object as according to step A), wherein during step B) the heat source exerts pressure on the material layer via the protective layer. An example of an applicable protective layer is a film manufactured from Teflon®
(polytetrafluoroethylene (PTFE)).
In an embodiment the method comprises step F), comprising of pressing the material layer against the plastic object at a distance close to the welding location with at least one retaining element. In this embodiment this at least one retaining element forms a separate element adjacently of the heat source and makes it possible to remove the heat source from the material layer after softening of the plastic by the heat source without the material layer being pulled loose from the plastic object. It is advantageous for this purpose for the heat source to be removed from the material layer after performing step B), wherein the material layer remains pressed against the plastic object by means of the at least one retaining element as according to step F). The at least one retaining element can be removed from the material layer after curing of the plastic object at the position of the welding location as according to step C).
It is generally advantageous for the material layer to be positioned in tensioned state relative to the plastic object during step A). The tensioned state prevents creases forming in the material layer, whereby the material layer can generally be better attached against the plastic object in predefined manner.
Steps A)-D) will generally be repeated at different welding locations on the material layer, whereby a spot weld pattern and/or line weld pattern will in fact be generated and whereby a strong, reliable and durable attachment of the material layer against the plastic object can be effected in relatively simple manner.
In an embodiment of the method according to the invention the temperature of the heat source lies between 230 °C and 245 °C during step B). A sheet manufactured from polypropylene with a melting point of 230 °C is usually applied as plastic object, and a non-woven material layer manufactured from polyester and/or polyamide (nylon) is applied as material layer. Polyester has a melting temperature of 245° C and polyamide has a melting temperature of 250 °C. Heating the heat source to a temperature within said temperature range can achieve that only the plastic sheet will melt position- selectively and that the material layer will remain in solid state. It is possible to envisage using other thermoplastic polymers instead of polypropylene.
The invention also relates to a device for realizing a welded connection between a material layer and a plastic object using heat, particularly for application of the method according to the invention, comprising: a support structure for supporting an assembly of an object manufactured at least partially from plastic, and a material layer, at least one heat source positioned displaceably relative to the support structure for pressing the material layer against the plastic object at a welding location in order to soften the plastic object at the welding location, and thereby adhere the plastic object to the material layer, and at least one retaining element for pressing the material layer against the plastic object at a part of the welding location or close to the welding location to allow the plastic object to cure at least at a part of the welding location. Advantages of applying a method which can be performed using a device according to the invention have already been described at length in the foregoing.
In an embodiment at least one heat source is formed by a blunt heat rod. The bluntness of the heat rod prevents the heat rod penetrating or at least damaging the material layer. On the other hand the term heat rod does however generally imply the presence of a contact surface of a limited size. The heat rod can also be used by a hollow pin, using which a round or double-round (concentric) weld impression can be formed. The shaping of the contact surface of the heat rod can be diverse and can for instance be round, oval, triangular, square or rectangular. The heat rod can be connected pivotally to the support structure to allow rotating of the heat rod on the material layer, whereby on the one hand the welding location can at least partially cool while on the other the heat rod continues to exert sufficient pressure on the material layer until the melted plastic has solidified sufficiently. In this latter exemplary embodiment the heat source and the retaining element take an integrated form. In another embodiment the heat rod and the at least one retaining element are embodied as separate elements, wherein the at least one retaining element is for instance formed by a retaining foot adapted to press the material layer against the plastic object a short distance from the welding location. After causing position-selective melting of the plastic the heat rod can be removed from the material layer, wherein the retaining foot continues to exert pressure on the material layer until the plastic has cooled sufficiently.
In an alternative embodiment at least one heat source is formed by a displaceable heat carriage adapted to slide over the material layer. Causing the heat carriage to slide over the material layer creates the situation where a welding location is first placed under pressure by the heat carriage, after which the heat carriage slides away from this welding location, whereby the welding location can cool and mutual adhesion of the material layer to the plastic object will occur. Because the heat carriage slides away from the above stated welding location, the heat carriage continues to exert pressure on the material layer in the direction of the plastic object, this generally enhancing the mutual adhesion between the material layer and the plastic object. It is generally advantageous to apply a protective layer between the heat carriage and the material layer which facilitates the sliding of the heat carriage and thereby prevents damage to the material layer. It is therefore advantageous for the device to comprise at least one holder for holding a protective layer such that the at least one heat source can exert pressure on the material layer via the protective layer. The result of attaching the material layer to the plastic object using the heat carriage is generally a line weld connection. The support structure is generally adapted to support the assembly of the plastic object and the material layer such that the material layer is supported by the plastic object. A contact surface of the plastic object will usually have a substantially horizontal orientation here, whereby the material layer can be supported. This embodiment is in general particularly advantageous from a logistical and structural viewpoint.
In an advantageous embodiment the device comprises tensioning means for tensioning the material layer relative to the plastic object, whereby the material layer can be attached against the plastic object relatively smoothly and in predefined manner. In an advantageous embodiment of the device according to the invention the device comprises a control unit for controlling the device as defined in the method according to the invention. It is generally advantageous here for the heat rod to comprise at least one temperature sensor, which temperature sensor is connected to the control unit. The temperature of the heat rod can in this way be monitored and regulated in order to have the operational temperature of the heat rod reach a temperature between the melting temperature of the plastic object, or at least of the contact surface of the plastic object, and the melting temperature of the material layer. The invention further relates to an assembly of an object manufactured at least partially from plastic and a material layer connected to the object by means of one or more welded connections and manufactured using a device according to the invention. A characteristic of the assembly is that the material layer is not (noticeably) damaged at the position of the welding location.
The invention will be elucidated on the basis of non- limitative exemplary embodiments shown in the following figures. Herein:
figures la- Id show a schematic view of successive method steps for realizing a welded connection between a plastic sheet and a material layer according to the invention by making use of a device according to the invention,
figures 2a-2e show a schematic view of alternative successive method steps for realizing a welded connection between a plastic sheet and a material layer according to the invention by making use of another device according to the invention,
figure 3 shows a schematic view of yet another device for realizing a welded connection between a plastic sheet and a material layer according to the invention, and
figures 4a-4e show a schematic view of other successive method steps for realizing a welded connection between a plastic sheet and a material layer according to the invention by making use of another device according to the invention. Figures la- Id show a schematic view of successive method steps for realizing a welded connection between a plastic sheet 1 and a material layer 2 according to the invention by making use of a device 3 according to the invention. Plastic sheet 1 is supported here by a displaceable support structure 4 of device 1, and material layer 2 is supported by plastic sheet 1. Plastic sheet 1 is manufactured from polypropylene and in this exemplary embodiment has a thickness of 10 millimetres. Material layer 2 is a non- woven manufactured from both polyamide and polyester, and in this exemplary embodiment has a thickness of 0.22 millimetres. In a first step (figure la) material layer 2 is positioned correctly relative to plastic sheet 1 and a blunt heat rod 5 is placed in a correct position above material layer 2. Heat rod 5 here comprises a heat-generating element 6 (shown schematically), as well as a cooling casing 7 to enable an outer side of heat rod 5 to be kept sufficiently cold to make durable mechanical displacement in a bearing unit (not shown) possible. In the operating situation the operational temperature of the core of heat rod 5 lies between the melting temperature of the plastic sheet, in this case 230°C, and the melting temperature of material layer 2, in this case about 245°C. In a second step (figure lb) heat rod 5 is moved in downward direction until a blunt underside 5a of heat rod 5 presses against material layer 2, and as such presses material layer 2 against plastic sheet 1. As a result of the selectively chosen operational temperature of heat rod 5 only plastic sheet 1 , and so not material layer 2, will melt in position-selective manner at the so-called welding location. The melted plastic is indicated by means of A. Through melting of the plastic, the plastic becomes soft and tacky and will adhere to material layer 2. Heat rod 5 is then tilted (figure lc), whereby heat rod 5 will rotate on material layer 2, wherein the contact surface between heat rod 5 and material layer 2 is made smaller. The result hereof is that a part of the material layer no longer being pressed by heat rod 5 and the part of plastic sheet 1 situated thereunder will cool to below the melting temperature, wherein the plastic will solidify at that location. The solidified plastic is indicated by means of B. Through solidification of the plastic the adhesion between material layer 2 and plastic sheet 1 will already be sufficiently strong to enable removal of heat rod 5 from material layer 2 without material layer 2 being pulled off plastic sheet 1 (figure Id), after which solidification of the plastic will be effected over the whole welding location. After displacing heat rod 5 in upward direction the support structure 4 can be displaced together with plastic sheet 1 and the material layer 2 attached thereto, after which a spot weld connection can once again be realized using heat rod 5.
Figures 2a-2e show a schematic view of alternative successive method steps for realizing a welded connection between a plastic sheet 8 and a material layer 9 according to the invention by making use of another device 10 according to the invention. Device 10 is adapted to realize a line weld connection. Plastic sheet 8 is supported releasably here by a displaceable support structure 11 of device 10, and material layer 9 is supported by plastic sheet 8. Plastic sheet 8 is manufactured from polymethyl methacrylate (PMMA) and in this exemplary embodiment has a thickness of 10 millimetres. Material layer 9 is a web manufactured from polyamide, and in this exemplary embodiment has a thickness of 0.22 millimetres. In a first step (figure 2a) material layer 9 is tensioned and positioned correctly relative to plastic sheet 8, and a heat-resistant protective layer 12 manufactured from Teflon® is positioned against a side of material layer 9 remote from plastic sheet 8. A heat carriage 13 is also placed in a correct position above material layer 9. Heat carriage 13 comprises here a heating coil 14 (shown schematically). In operating situation the operational temperature of heat carriage 13 lies between the melting temperature of the plastic sheet, in this case 230 °C, and the melting temperature of material layer 9, in this case about 245 °C. In a second step (figure 2b) heat carriage 13 is moved in downward direction until heat carriage 13 engages under bias on material layer 9 and as such presses material layer 9 against plastic sheet 8. As a result of the selectively chosen operational temperature of heat carriage 13 only plastic sheet 8, and so not material layer 9, will melt in position- selective manner at the so-called welding location. The melted plastic is indicated by means of A. Through melting of the plastic, the plastic becomes soft and tacky and will adhere to material layer 9. Heat carriage 13 is then displaced parallel to material layer 9 and plastic sheet 8, wherein heat carriage 13 continues to exert a downward pressure on material layer 9 (figure 2c). This relative displacement can be realized by actively displacing heat carriage 13 and/or by actively displacing support structure 11 with plastic sheet 8, material layer 9 and protective layer 2 thereon. The result hereof is that a part of the original welding location is no longer being heated by heat carriage 13 and will thus cool to below the melting point of the plastic, this resulting in solidifying of the plastic (see B). Due to the relative displacement an adjacent part of plastic sheet 11 will moreover be heated and melted in order to realize a continuous welded connection. A line weld connection can in this way be realized (figure 2d). After realizing the line weld connection the heat carriage 13 is removed from material layer 9 (figure 2e) and the intermediate protective layer 12 can also be removed. As shown in figure 2e, the whole line weld connection has solidified. The above stated process can optionally be repeated at a distance from the completed line weld connection in order to create a line weld pattern, which can be advantageous to enable improvement of the overall adhesion of material layer 9 to plastic sheet 8. In an alternative embodiment of device 10 heat carriage 13 is in stationary position and support structure 11, together with plastic sheet 8 and material layer 9, is displaced linearly relative to heat carriage 13. Protective layer 12 is advanced at the same speed as the displacement speed of support structure 11, plastic sheet 8 and material layer 9, wherein protective layer 12 can be formed by an endless conveyor belt.
Figure 3 shows a schematic view of yet another device 15 for realizing a welded connection between a plastic sheet 16 and a material layer 17 according to the invention. Device 15 comprises a support structure 18 for supporting plastic sheet 16 and material layer 17 positioned thereon. By means of a heat rod 1 forming part of device 15 a welded connection can be realized by only position-selective melting of plastic sheet 16 as described at length in the foregoing. Device 15 further comprises a displaceabie hollow cylindrical foot 20 in which heat rod 19 is displaceably received. The orientation of material layer 17 relative to plastic sheet 16 can be fixed
mechanically around the welding location by means of foot 20, wherein heat rod 19 can realize the actual welded connection between material layer 17 and plastic sheet 16. Solidification, and thereby consolidation, of the welded connection can take place by moving heat rod 19 in upward direction after melting of the plastic at the position of the welding location and causing foot 20 to continue exerting a downward force on material layer 17. After curing of the welded connection, foot 20 can be removed from material layer 17, whereby the welding process is completed. Foot 20 can optionally be provided with at least one cooling element so as to be able to prevent (substantial) heating of foot 20. It will be apparent that this welding process can be performed on multiple parts of material layer 17 and plastic sheet 16, whereby a spot weld pattern can be generated. Because material layer 17 is not (noticeably) damaged during this process, the assembly of plastic sheet 16 and material layer 17 attached thereto obtained via this method can generally be applied particularly advantageously in an indirect static cooler, in particular a dew point cooler, of the type described in the Netherlands patent
NL2000079.
Figures 4a-4e show a schematic view of other successive method steps for realizing a welded connection between a plastic sheet 21 and a material layer 22 according to the invention by making use of another device 23 according to the invention. Plastic sheet 21 is supported here by a displaceabie support structure 24 of device 23 and material layer 22 is supported by plastic sheet 21. Plastic sheet 21 is manufactured in this exemplary embodiment from polypropylene and has a thickness of 20 millimetres. Material layer 22 is a non- woven manufactured from both polyamide and polyester, and in this exemplary embodiment has a thickness of 0.25 millimetres. In a first step (figure 4a) material layer 22 is positioned correctly relative to plastic sheet 21 and a pivotally suspended hollow heat rod 25 is placed in an initial tilted position above material layer 22. Heat rod 25 here comprises a heat-generating element 26 (shown schematically) and a cooling casing 27 to enable an outer side of heat rod 25 to be kept sufficiently cold to make durable mechanical displacement in a bearing unit (not shown) possible. In the operating situation the operational temperature of the underside of heat rod 25 lies between the melting temperature of the plastic sheet, in this case 230 °C, and the melting temperature of material layer 22, in this case about 245 °C. In a second step (figure 4b) heat rod 25 is moved in downward direction until a part of underside 25a of heat rod 25 presses against material layer 22 and as such presses material layer 22 against plastic sheet 21. As a result of the selectively chosen operational temperature of heat rod 25 only plastic sheet 21, and so not material layer 22, will melt in position- selective manner at the so-called welding location. The melted plastic is indicated by means of A. Through melting of the plastic, the plastic becomes soft and tacky and will adhere to material layer 22. Because support structure 24, and thereby sheet 21 and material layer 22 lying thereon, is displaced to the right (see arrows), heat rod 25 will tilt and rotate on material layer 22, wherein the contact surface between heat rod 25 and material layer 22 is first enlarged (figure 4c) and then made smaller (figure 4d), after which heat rod 25 will be removed from material layer 22 (figure 4e). The result hereof is that a part of the material layer no longer being pressed by heat rod 25 and the part of plastic sheet 21 situated thereunder will cool to below the melting temperature, wherein the plastic will solidify at that location. The solidified plastic is indicated by means of B. Through solidification of the plastic the adhesion between material layer 22 and plastic sheet 21 will be sufficiently strong to enable removal of heat rod 5 from material layer 2 without material layer 22 being pulled off plastic sheet 21 (figure 4e), after which the annular solidification of the plastic will be effected over the whole welding location. After displacing heat rod 25 in upward direction support structure 24 can be displaced together with plastic sheet 21 and material layer 22 attached thereto, after which an annular welded connection can once again be realized using heat rod 25. It will further be apparent that the invention is not limited to the exemplary
embodiments shown and described here, but that within the scope of the appended claims numerous variants are possible which will be self-evident to the skilled person in this field.

Claims

Claims
1. Method for realizing a welded connection between a material layer and a plastic object using heat, comprising of:
A) positioning a material layer with a first melting temperature relative to an object manufactured at least partially from plastic with a second melting temperature,
B) pressing the material layer against the plastic object at a welding location by means of a heat source, wherein the temperature of the heat source lies between the first melting temperature of the material layer and the second melting temperature of the plastic object, whereby the plastic object will soften at the welding location and adhere to the material layer,
C) allowing the plastic object to cure by means of cooling at least at a part of the location, wherein the material layer remains pressed against the plastic object at and/or close to the location, and
D) discontinuing the pressure exerted on the material layer and the plastic object at the position of the welding location after curing of the plastic object.
2. Method as claimed in claim I, wherein the heat source is displaced relative to the material layer during step C), whereby the pressure exerted on the material layer by the heat rod at the position of the welding location is at least partially relieved.
3. Method as claimed in claim 2, wherein the contact surface between the heat source and the material layer is made smaller during step C).
4. Method as claimed in claim 2, wherein by displacing the heat source relative to the material layer a new welding location is created where the material layer can be connected to the plastic object.
5. Method as claimed in any of the claims 2-4, wherein the displacement of the heat source relative to the material layer during step C) takes place by rotating the heat rod on the material layer.
6. Method as claimed in any of the claims 2-4, wherein the displacement of the heat source relative to the material layer during step C) takes place by allowing the heat source to slide over the material layer.
7. Method as claimed in any of the foregoing claims, wherein the method comprises step E), comprising of positioning a protective layer on a side of the material layer remote from the plastic object after positioning of the material layer relative to the plastic object as according to step A), wherein during step B) the heat source exerts pressure on the material layer via the protective layer.
8. Method as claimed in any of the foregoing claims, wherein the method comprises step F), comprising of pressing the material layer against the plastic object at a distance close to the welding location with at least one retaining element.
9. Method as claimed in claim 8, wherein the heat source is removed from the material layer after performing step B), wherein the material layer remains pressed against the plastic object by the at least one retaining element as according to step F).
10. Method as claimed in claim 8 or 9, wherein the at least one retaining element is removed from the material layer after curing of the plastic object at the position of the welding location as according to step C).
11. Method as claimed in any of the foregoing claims, wherein the material layer is positioned in tensioned state relative to the plastic object during step A).
12. Method as claimed in any of the foregoing claims, wherein steps A)-D) are repeated at different welding locations on the material layer.
13. Method as claimed in any of the foregoing claims, wherein the temperature of the heat source lies between 230 °C and 245 °C during step B).
14. Method as claimed in any of the foregoing claims, wherein a surface of the plastic object facing toward the material layer is manufactured from a thermoplastic polymer, in particular polypropylene.
15. Method as claimed in any of the foregoing claims, wherein the material layer is formed by a web.
16. Method as claimed in any of the foregoing claims, wherein the material layer is manufactured at least partially from plastic.
17. Device for realizing a welded connection between a material layer and a plastic object using heat, particularly for application of the method as claimed in any of the claims 1-16, comprising:
- a support structure for supporting an assembly of an object manufactured at least partially from plastic, and a material layer,
at least one heat source positioned displaceably relative to the support structure for pressing the material layer against the plastic object at a welding location in order to soften the plastic object at the welding location, and thereby adhere the plastic object to the material layer, and
at least one retaining element for pressing the material layer against the plastic object at a part of the welding location or close to the welding location to allow the plastic object to cure at least at a part of the welding location.
18. Device as claimed in claim 17, wherein at least one heat source is formed by a blunt heat rod.
19. Device as claimed in claim 18, wherein the heat rod is connected pivotally to the support structure to allow rotating of the heat rod on the material layer.
20. Device as claimed in any of the claims 17-19, wherein the heat source and the retaining element take an integrated form.
21. Device as claimed in any of the claims 17-19, wherein the at least one retaining element is formed by a retaining foot adapted to press the material layer against the plastic object a short distance from the welding location.
22. Device as claimed in any of the claims 17-21, wherein at least one heat source is formed by a displaceable heat carriage adapted to slide over the material layer.
23. Device as claimed in any of the claims 17-22, wherein the support structure is adapted to support the assembly of the plastic object and the material layer such that the material layer is supported by the plastic object.
24. Device as claimed in any of the claims 17-23, wherein the device comprises tensioning means for tensioning the material layer relative to the plastic object.
25. Device as claimed in any of the claims 17-24, wherein the device comprises at least one holder for holding a protective layer such that the at least one heat source can exert pressure on the material layer via the protective layer.
26. Device as claimed in any of the claims 17-25, wherein the device comprises a control unit for controlling the device in accordance with the method as claimed in any of the claims 1-16.
27. Device as claimed in claim 26, wherein the heat rod comprises at least one temperature sensor, which temperature sensor is connected to the control unit.
28. Assembly of an object manufactured at least partially from plastic and a material layer connected to the object and manufactured using a device as claimed in any of the claims 17-27.
PCT/NL2010/050794 2009-11-26 2010-11-26 Method and device for connecting a material layer to a plastic object WO2011065827A1 (en)

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