Dielectric Weldable Polymer Blend for Rapid RF Sealing
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Solution Overview
Problem
Current dielectric welding techniques are limited to specific polymers with high dielectric loss factors, excluding flexible and transparent polymers with low dissipation factors that are typically sealed thermally, hindering efficient commercialization due to lengthy thermal sealing processes.
Innovation Solution
A blend of inert polymers and elastomeric polar polymers is developed, modifying the dielectric properties of inert polymers to make them weldable with high frequency or radiofrequency energy, enabling sealing of previously non-weldable materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal sealing process is used on polymeric materials, then sealing is achieved, but processing time is lengthy (several minutes)
Solution Approach 1:
The patent replaces the thermal sealing process with a dielectric welding process that uses high frequency electromagnetic energy and pressure instead of heat. This substitution reduces processing time from several minutes to a fraction of the time while achieving reliable seals, directly resolving the contradiction between sealing quality and processing time.
2Loss of time
If dielectric welding technique is used, then processing time is reduced, but application is limited to particular polymers with high dielectric loss factor
Solution Approach 1:
The patent modifies the dielectric properties of inert polymers by blending them with elastomeric polar polymers, changing the dissipation factor from low (inert) to high (weldable). This parameter change enables previously incompatible polymers to be processed with dielectric welding, resolving the contradiction between processing speed and polymer compatibility.
Solution Approach 2:
The patent creates a composite material system consisting of inert polymer blended with elastomeric polar polymer. This composite approach combines the desirable physical properties of inert polymers with the dielectric weldability of polar polymers, expanding the range of materials that can be efficiently sealed while maintaining processing speed advantages.
3Strength
If polymers with desirable physical properties (flexible, transparent) are selected, then mechanical properties are improved, but these polymers cannot be sealed with dielectric energy due to low dissipation factor
Solution Approach 1:
The patent formulates composite materials that combine inert polymers (providing flexibility and transparency) with elastomeric polar polymers (providing dielectric weldability). This composite approach allows the material to maintain desirable mechanical properties while gaining the capability to be sealed with dielectric energy, resolving the contradiction between mechanical properties and sealing capability.
Solution Approach 2:
The patent introduces elastomeric polar polymer components specifically to modify the dielectric properties at the sealing interface, while the bulk material retains the physical properties of the inert polymer. This localized modification enables dielectric welding without compromising the overall mechanical properties of the material.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution allows for rapid sealing of materials with desirable mechanical and physical properties, such as flexibility and clarity, while reducing processing time and maintaining integrity under pressure tests, suitable for various industrial applications.
Implementation Method 1
The dielectric welding technique, also known as high frequency or radiofrequency welding, uses both high frequency electromagnetic energy and pressure to create a seal
Implementation Method 2
These particular polymers are conducive to dielectric welding due to their high dielectric loss factor (i.e. greater than 0.1) or dissipation factor tangent delta of the polymeric material
Data Source
AI summary
A dielectric weldable material includes a blend of at least two components including an inert polymer and an elastomeric polar polymer. A method of forming a bond includes providing a substrate having a first end and a second end, wherein the substrate includes a blend of at least two components including an inert polymer and an elastomeric polar polymer. The method further includes bonding the first end and second end of the substrate with high frequency electromagnetic energy.