Halogenated Rubber Seal Welding to Polyurethane
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Solution Overview
Problem
Conventional methods for joining rubber seals to thermoplastic polyurethane components in garments are labor-intensive and prone to leaks, lacking a robust and efficient welding solution.
Innovation Solution
The process involves halogenating the surface of natural rubber seals and directly welding the thermoplastic polyurethane components to the halogenated rubber surface using RF or impulse welding, eliminating intermediate layers and enhancing the thermoplastic properties of the rubber for a strong and leak-free join.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional adhesive and stitching methods are used to join rubber seals to polyurethane components, then the joining process is robust and produces reliable bonds, but the manufacturing process becomes labor-intensive and time-consuming
Solution Approach 1:
The patent replaces the mechanical joining system (adhesive application, positioning, and stitching) with a thermal welding system. The polyurethane component is welded directly to the rubber seal using heat and pressure, eliminating the need for adhesives and stitching operations. This substitution transforms a multi-step mechanical process into a single-step thermal process, significantly improving productivity while maintaining bond reliability.
Solution Approach 2:
The patent changes the physical state of the polyurethane component by heating it to its melting point during the welding process. This parameter change allows the polyurethane to transition from a solid state to a molten state, enabling it to flow and fuse with the rubber seal surface. After cooling, the polyurethane solidifies to form a strong, permanent bond, replacing the need for adhesive bonding.
2Ease of manufacture
If adhesive tape and stitching are used to join rubber and polyurethane, then the join can be made with existing methods, but the process is complex and requires multiple steps including careful positioning
Solution Approach 1:
The patent merges multiple joining operations (adhesive application, positioning, bonding, and reinforcement stitching) into a single welding operation. The welding process simultaneously achieves positioning, bonding, and sealing in one step, eliminating the sequential complexity of the conventional multi-step process. This consolidation dramatically simplifies the manufacturing procedure while reducing the number of required operations.
Solution Approach 2:
The patent introduces heat as an intermediary medium to facilitate the joining process. By applying heat to the polyurethane component, the process enables direct fusion between the polyurethane and rubber seal without requiring adhesive intermediaries. This thermal intermediary simplifies the joining mechanism by creating a direct molecular bond through melting and solidification, replacing the complex adhesive-stitching system.
3Reliability
If rubber seals are joined to polyurethane using conventional methods, then the components can be assembled, but the joins may be prone to leaks and lack robustness
Solution Approach 1:
The patent replaces mechanical joining methods (adhesive bonding and stitching) with thermal welding to achieve superior seal integrity. The welding process creates a homogeneous molecular bond between the polyurethane and rubber seal, eliminating potential leak paths that may exist in mechanically joined assemblies. This substitution ensures leak-free performance while reducing manufacturing time through the elimination of multiple bonding steps.
Solution Approach 2:
The patent utilizes parameter changes in the polyurethane material by heating it above its melting point during welding. This thermal parameter change allows the polyurethane to become pliable and fuse completely with the rubber seal surface, creating a seamless, leak-proof joint. The subsequent cooling and solidification locks in this intimate bond, ensuring robust sealing performance that exceeds conventional joining methods.
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
This method achieves a strong and leak-free bond between rubber and thermoplastic components, surpassing the strength and reliability of conventional adhesive-based methods, with demonstrated shear and peel strengths significantly higher than typical tape joints.
Implementation Method 1
the natural rubber seal has a halogenated surface and the process comprises the steps of bringing the polyurethane component into contact with the halogenated surface of the natural rubber seal and RF welding or impulse welding the polyurethane component to the halogenated surface of the rubber seal
Implementation Method 2
RF welding or impulse welding the polyurethane component to the halogenated surface of the rubber seal
Implementation Method 3
RF welding or impulse welding the polyurethane component to the halogenated surface of the rubber seal
Implementation Method 4
The thermoplastic polyurethane and halogenated rubber therefore fuse together during the welding step
Data Source
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AI summary
A process for making an article comprising a thermoplastic component (4) and a rubber component (3) having an halogenated surface in which the thennoplastic component is welded directly to the halogenated surface of the rubber component by, for example, RF or impulse welding. The product comprises a rubber component having an halogenated surface and a thermoplastic component in which the halogenated surface of the rubber component and the thermoplastic component are fused together.