Adapter for welding objects to plastic

• US 20020020487A1
• Filed: 08/03/2001
• Published: 02/21/2002
• Est. Priority Date: 08/11/2000
• Status: Active Grant

• Current Assignee: Visteon Global Technologies Incorporated (Visteon Corporation)
• Original Assignee: Visteon Global Technologies Incorporated (Visteon Corporation)
• Inventors: Fish, Duane, Vorenkamp, Erich James, Vaughn, Lawrence Eugene III
• Granted Patent: US 6,726,967 B2
• Time in Patent Office: Days
• US Class Current: 156/244.19
• CPC Class Codes: B29B 13/023 Half-products, e.g. films, plates
• CPC Class Codes: B29C 2035/0822 using IR radiation
• CPC Class Codes: B29C 2049/2017 outside the article
• CPC Class Codes: B29C 49/20 of articles having inserts or reinforcements ; Handling of inserts or reinforcements
• CPC Class Codes: B29C 49/22 using multilayered preforms or parisons
• CPC Class Codes: B29C 51/12 of articles having inserts or reinforcements
• CPC Class Codes: B29C 51/14 using multilayered preforms or sheets
• CPC Class Codes: B29C 51/267 Two sheets being thermoformed in separate mould parts and joined together while still in the mould B29C49/0691 takes precedence
• CPC Class Codes: B29C 51/421 of preforms, specially adapted for thermoforming preheating sheets in general B29B13/023; B29C51/427 takes precedence
• CPC Class Codes: B29C 65/028 making use of inherent heat, i.e. the heat for the joining comes from the moulding process of one of the parts to be joined
• CPC Class Codes: B29C 66/1312 Single flange to flange joints, the parts to be joined being rigid the parts to be joined being flexible B29C66/133
• CPC Class Codes: B29C 66/53245 said articles being hollow
• CPC Class Codes: B29C 66/61 Joining from or joining on the inside for making tubes by bending sheets and joining from the inside B29C53/387
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/7234 comprising a barrier layer
• CPC Class Codes: B29K 2023/065 HDPE, i.e. high density polyethylene
• CPC Class Codes: B29K 2023/086 EVOH, i.e. ethylene vinyl alcohol copolymer
• CPC Class Codes: B29K 2105/16 Fillers
• CPC Class Codes: B29K 2995/0067 non-permeable
• CPC Class Codes: B29K 2995/0069 non-permeable
• CPC Class Codes: B29L 2031/7172 : Fuel tanks, jerry cans
• CPC Class Codes: B60K 15/03177 : made of non-metallic material, e.g. plastics, or of a combination of non-metallic and metallic material B60K15/03006 takes precedence
• CPC Class Codes: B60K 15/03519 : Valve arrangements in the vent line
• CPC Class Codes: B60K 15/077 : with means modifying or controlling distribution or motion of fuel, e.g. to prevent noise, surge, splash or fuel starvation
• CPC Class Codes: B60K 2015/03111 : Swirl pots
• CPC Class Codes: B60K 2015/0344 : comprising baffles
• CPC Class Codes: B60K 2015/0777 : in-tank reservoirs or baffles integrally manufactured with the fuel Tank
• CPC Class Codes: F16B 9/052 : the intermediate member having a radial flange secured to the flat surface
• CPC Class Codes: Y10S 264/65 : Processes of preheating prior to molding
• CPC Class Codes: Y10T 428/13 : Hollow or container type article [e.g., tube, vase, etc.]
• CPC Class Codes: Y10T 428/1352 : Polymer or resin containing [i.e., natural or synthetic]
• CPC Class Codes: Y10T 428/1383 : Vapor or gas barrier, polymer derived from vinyl chloride or vinylidene chloride, or polymer containing a vinyl alcohol unit is sandwiched between layers [continuous layer]

Abstract

An adapter provides for mounting an object on plastic. The adapter comprises a body coupled with at least two feet. The feet are weldable to the surface of the plastic while the plastic is in a molten state. The adapter also includes a coupling mechanism coupled with the body. The coupling mechanism is operable to couple the object with the adapter.

Claims

1. An adapter for mounting an object on plastic while the plastic is in a molten state, the adapter comprising:

a body;

at least two feet coupled with the body, the feet extending away from the body in different directions, the at least two feet weldable to the surface of the plastic; and

a coupling mechanism coupled with the body, the coupling mechanism with provision to couple the object with the body.

2. The adapter of claim 1, wherein the thickness of each of the at least two feet decreases as the at least two feet extend away from the body.

3. The adapter of claim 1, wherein the feet are operable to absorb stresses generated between the adaptor and the surface of the plastic.

4. The adapter of claim 1, wherein the at least two feet comprise plastic resin.

5. The adapter of claim 1, wherein the at least two feet and the body comprise one continuous structure.

6. The adapter of claim 1, wherein the at least two feet are operable to melt together with the surface of the plastic to form a surface weld.

7. The adapter of claim 1, wherein the coupling mechanism comprises at least one of a weld, a snap fit connection, a screw connection, a friction fit, a clamp, a keeper, a latch, provisions to mold to the object and provisions to overmold the object.

8. The adapter of claim 1, wherein the at least two feet extend away while maintaining slits therebetween.

9. The adapter of claim 1, wherein the at least two feet are operable to limit the depth of penetration into the surface of the plastic.

10. An adapter for use in mounting an object on plastic while the plastic is in a molten state, the adapter comprising:

a plurality of plastic feet each having a distal end and a proximal end;

a body couple with the distal end, the proximal end of each of the plastic feet suspended away from the body to form a weld zone with provision to engage the surface of the plastic; and

a coupling mechanism coupled with the body, the coupling mechanism operable to couple with the object.

11. The adapter of claim 10, wherein the thickness of material forming the distal end of each of the plastic feet is less than the thickness of material forming the proximal end of each of the plastic feet.

12. The adapter of claim 10, wherein the surface area of the distal end is smaller than the surface area of the proximal end.

13. The adapter of claim 10, wherein the plastic feet are operable to absorb stresses generated by forces acting other than parallel with the central axis of the adapter.

14. The adapter of claim 10, wherein the coupling mechanism is integrally formed with the object.

15. The adapter of claim 10, wherein the weld zone is operable to engage the surface of the plastic by formation of a surface weld.

16. The adapter of claim 10, wherein the weld zone comprises a lip and a relatively flat surface, the lip and the relatively flat surface positionable on the surface of the plastic.

17. The adapter of claim 10, wherein each of the plastic feet form a flower petal shape.

18. The adapter of claim 10, wherein the object comprises material incompatible with the surface of the plastic.

19. The adapter of claim 10, wherein the plastic feet and the plastic are formed from compatible materials.

20. An adapter for mounting a fuel system component to a wall of a plastic fuel tank while the wall is in a molten state, the adapter comprising:

a body, the body forming a longitudinally extending hollow housing with a distal end and a proximal end;

the distal end comprising a coupling mechanism operable to couple with the fuel system component;

a plurality of slits in the body, the slits extending from the proximal end a predetermined distance toward the distal end; and

a portion of the body adjacent the slits formed to provide a weld zone near the proximal end, the weld zone weldable to the surface of the wall.

21. The adapter of claim 20, wherein the portions of the body are operable to flex in response to forces acting other than parallel with the central axis of the body.

22. The adapter of claim 20, wherein the thickness of the plastic resin forming the weld zone is less than the thickness of the remainder of the body.

23. The adapter of claim 20, wherein a uniform distance between adjacent portions of the body defines the slits.

24. The adapter of claim 20, wherein each portion of the body outwardly extends away from the central axis of the body.

25. The adapter of claim 20, wherein the portion of the body forms a segmented funnel shape.

26. The adapter of claim 20, wherein the weld zone forms an annular ring intermittently broken by the slits.

27. The adapter of claim 20, wherein the weld zone comprises a relatively flat surface and a lip, the relatively flat surface operable to resisting tilting of the adapter or decoupling from the surface of the wall during a weld operation.

29. The adapter of claim 28, wherein d) comprises melting the feet and the surface of the plastic together.

30. The method of claim 28, wherein d) comprises heating the feet prior to contacting the surface of the plastic.

31. The adapter of claim 28, wherein e) comprises absorbing stresses within the surface weld with the feet.

32. The adapter of claim 28, further comprising:

f) subjecting the plastic and the adapter to fuel; and

g) absorbing stresses produced by independent swelling of the plastic and the feet.

33. The adapter of claim 28, wherein b) comprises:

forming the adapter as a hollow cylindrical housing; and

forming the feet as part of the hollow cylindrical housing.

34. The adapter of claim 28, wherein d) comprises maintaining the object at ambient temperature.

35. The adapter of claim 28, wherein c) comprises molding the adapter to the object.

36. The adapter of claim 28, wherein c) comprises overmolding the adapter onto the object.

37. The adapter of claim 28, wherein c) comprises mechanically coupling the adapter with the object.

28. A method of coupling an object to plastic, the method comprising:

a) heating the plastic to a molten state;

b) providing an adapter comprising a body, a plurality of feet and a coupling mechanism;

c) coupling an object with the coupling mechanism;

d) advancing the feet into contact with a surface of the plastic to form a surface weld; and

e) cooling the plastic and the adapter.