Thermoplastic Welding Tooling Deformable Pressurizers
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Solution Overview
Problem
Conventional thermoplastic welding techniques often result in welding errors such as squeeze out and delamination due to incorrect pressure application, and bladder imprints, as they lack mechanisms to hold components together with precise pressure from various angles without imprinting.
Innovation Solution
A thermoplastic welding assembly that includes a first plate with a slot for a welding probe and a second plate with plunger cavities, featuring movable plungers and deformable pressurizers made of non-conductive materials that compress to securely hold components during welding, ensuring even pressure distribution and preventing imprint issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional benches and presses are used to apply pressure during welding, then the components can be held together, but welding errors like squeeze out or delamination occur due to incorrect pressure application
Solution Approach 1:
The patent applies parameter changes by transitioning from rigid pressurizers to deformable pressurizers made of elastomeric or foam materials. This material property change allows the pressurizers to conform to component surfaces and distribute pressure evenly, preventing squeeze out and delamination while maintaining reliable welding.
Solution Approach 2:
The patent uses flexible pressurizers made of deformable materials such as elastomeric material or foam material. These flexible pressurizers can deform to match the contours of the thermoplastic components, providing uniform pressure distribution across the welding surface and eliminating the pressure application inaccuracies that cause welding defects.
2Force
If bladders are used to push components together during welding, then pressure can be applied, but bladder imprints are found where the bladder rubbed off or imprinted on the components
Solution Approach 1:
The patent employs disposable or replaceable pressurizer elements made of deformable materials that can be easily replaced. These pressurizers are designed to be consumed or replaced after a certain number of uses, preventing the accumulation of imprints and surface damage that would occur with reusable rigid pressurizers.
Solution Approach 2:
The patent changes the material parameter of the pressurizer from rigid to deformable (elastomeric or foam material). This parameter change allows the pressurizer to deform and conform to the component surface, distributing pressure evenly and preventing the localized high-pressure spots that cause bladder imprints.
3Stress or pressure
If rigid pressurizers are used to hold components together, then pressure can be maintained, but the components cannot be held with correct pressure from various angles
Solution Approach 1:
The patent uses flexible pressurizers made of deformable materials that can adapt to different component geometries. These pressurizers can be positioned at various angles and locations, conforming to the component surfaces they contact, thereby providing correct pressure application from multiple angles and positions.
Solution Approach 2:
The patent introduces dynamic adaptability through deformable pressurizers that can change their shape and positioning during the welding process. Unlike rigid pressurizers with fixed geometries, these deformable pressurizers can adjust to the specific contours and angles of the thermoplastic components, providing versatile pressure application.
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 effectively prevents squeeze out and delamination, providing a secure and precise hold on thermoplastic components during welding, allowing for strong and consistent welds without imprinting, thus improving the quality of thermoplastic welds.
Implementation Method 1
A heat sink is positioned within the slot of the first plate for dissipating heat from the thermoplastic components during welding
Implementation Method 2
One particular type of thermoplastic welding uses electromagnetic induction to heat components without contacting the components. An induction welding probe emits an inductive field toward two thermoplastic components to be joined, which induces heat in the components
Implementation Method 3
the pressurizers are made of a deformable material that compresses when pushed into contact the thermoplastic components, providing a secure hold of the thermoplastic components during welding
Data Source
AI summary
A thermoplastic welding assembly includes a structural cage that supports a press and one or more hydraulic and pneumatic actuators. The press includes first and second plates that movable toward and away from each other to load and remove thermoplastic components to be held together for thermoplastic welding. Specifically, the first plate of the press includes non-conductive tooling inserts that are positioned to form a slot for a welding prove, and the second plates includes non-conductive tooling inserts that form cavities for plungers to move through. Plungers that are movable using the actuators are positioned in the cavities of the second plate, and compressible pressurizers are attached to the ends of the plungers. An operator uses electrical controls to move the plungers in the plunger cavities toward the thermoplastic components in the press to drive the pressurizers into the thermoplastic components and provide stabilizing pressure on the components during welding.