Temperature controlled polymer composition for inductive control heating using electrical conductive and magnetic particles

• US 20090004466A1
• Filed: 11/13/2007
• Published: 01/01/2009
• Est. Priority Date: 06/26/2007
• Status: Active Grant

• Current Assignee: Tas Acquisition Co., LLC
• Original Assignee: Emabond Solutions, LLC
• Inventors: LaMarca, Drew P., Agosto, Bryan
• Granted Patent: US 7,984,738 B2
• Time in Patent Office: Days
• US Class Current: 428/338
• CPC Class Codes: B29C 65/3612 comprising fillers
• CPC Class Codes: B29C 65/3676 being metallic
• 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 66/7392 characterised by the material of at least one of the parts being a thermoplastic
• CPC Class Codes: B29C 66/73921 characterised by the materials of both parts being thermoplastics
• CPC Class Codes: B29C 66/7394 characterised by the material of at least one of the parts being a thermoset
• CPC Class Codes: B29C 66/73941 characterised by the materials of both parts being thermosets
• CPC Class Codes: B29C 66/91411 of the parts to be joined, e.g. the joining process taking the temperature of the parts to be joined into account
• CPC Class Codes: B29C 66/91431 the temperature being kept constant over time
• CPC Class Codes: B29C 66/91443 following a temperature-time profile B29C65/38 takes precedence
• CPC Class Codes: B29C 66/91651 by controlling or regulating the heat generated by Joule heating or induction heating
• CPC Class Codes: B29C 70/88 characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
• CPC Class Codes: B29K 2023/06 PE, i.e. polyethylene
• CPC Class Codes: B29K 2023/086 EVOH, i.e. ethylene vinyl alcohol copolymer
• CPC Class Codes: B29K 2023/12 PP, i.e. polypropylene
• CPC Class Codes: B29K 2067/00 Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2067/003 PET, i.e. poylethylene terephthalate
• CPC Class Codes: B29K 2069/00 Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2071/00 Use of polyethers , e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2071/12 PPO, i.e. polyphenylene oxide; PPE, i.e. polyphenylene ether
• CPC Class Codes: B29K 2075/00 : Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2077/00 : Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2079/085 : Thermoplastic polyimides, e.g. polyesterimides, PEI, i.e. polyetherimides, or polyamideimides; Derivatives thereof
• CPC Class Codes: B29K 2081/04 : Polysulfides, e.g. PPS, i.e. polyphenylene sulfide or derivatives thereof
• CPC Class Codes: B29K 2081/06 : PSU, i.e. polysulfones; PES, i.e. polyethersulfones or derivatives thereof
• CPC Class Codes: B29K 2101/10 : Thermosetting resins
• CPC Class Codes: B29K 2101/12 : Thermoplastic materials
• CPC Class Codes: B29K 2105/203 : Magnetic parts
• CPC Class Codes: B29K 2995/0005 : Conductive
• CPC Class Codes: B29K 2995/0008 : Magnetic or paramagnetic
• CPC Class Codes: C08K 2201/001 : Conductive additives
• CPC Class Codes: C08K 2201/01 : Magnetic additives
• CPC Class Codes: H01F 1/26 : by macromolecular organic substances
• CPC Class Codes: Y10T 428/268 : Monolayer with structurally defined element

Abstract

A polymer composition with a polymer matrix material and magnetic particles. The composition is selectively electro-magnetically heatable by an electrical induction energy frequency that is pulse width modulated through variable time cycles to provide controlled heating.

Claims

1. A polymer composition, comprising:

a polymer matrix material and magnetic particles, whereby the composition is selectively electro-magnetically heatable by an electrical induction energy frequency that is pulse width modulated through variable time cycles.

2. The polymer composition according to claim 1, and further comprising electrically conductive particles.

3. The polymer composition according to claim 2, wherein the particles are greater than or equal to about 10 nanometers in size.

4. The polymer composition according to claim 2, wherein the electrically conductive and magnetic particles are evenly distributed in the polymer matrix material.

5. The polymer composition according to claim 1, wherein the polymer matrix material includes polymer matrix particles greater than or equal to about 1 micron in size.

6. The polymer composition according to claim 2, wherein the electrically conductive and magnetic particles are present from about 1% to about 75% by weight.

7. The polymer composition according to claim 1, wherein the polymer matrix material is a thermoplastic material.

8. The polymer composition according to claim 7, wherein the thermoplastic material is selected from the group consisting of:

poly(etheretherketone), polyetherketoneketone, poly(etherimide), polyphenylene sulfide, poly(sulfone), polyethylene terephthalate, polyester, polyamide, polypropylene, polyurethane, polyphenylene oxide, polycarbonate, polypropylene/polyamide, polypropylene/ethylene vinyl alcohol, polyethylene, polyolefin oligomers, liquid modified polyolefins or combinations thereof.

9. The polymer composition according to claim 2, wherein the electrically conductive and magnetic particles have a Curie temperature (Tc) that is greater than a melting temperature of the polymer matrix material.

10. The polymer composition according to claim 5, wherein the polymer matrix material is viscous and includes a solvent, alcohol or aqueous dispersions, the micron sized polymer matrix particles and oxygenated coatings.

11. A thermoset composition, comprising:

a viscous thermoset matrix material including a thermoset adhesive or encapsulate and micron sized polymer matrix particles; and

magnetic particles, whereby the composition is electromagnetically heatable by an electrical induction energy frequency that is pulse width modulated through variable time cycles.

12. The thermoset composition according to claim 11, wherein the micron sized polymer matrix particles have a Curie temperature (Tc) that is greater than a curing temperature of the thermoset matrix material.

13. A method for controlled temperature bonding, comprising the steps of:

dispersing magnetic particles in a polymer matrix material to form a polymer composition;

electromagnetically heating the composition with an electrical induction energy frequency; and

pulse modulating the frequency through variable time cycles.

14. The method according to claim 13, including dispersing electrically conductive particles in the polymer matrix material.

15. The method according to claim 14, wherein the frequency is in a range of 80 KHz to 30 MHz.

16. The method according to claim 14, including evenly distributing the electrically conductive and magnetic particles in the polymer matrix material.

17. The method according to claim 14, wherein each frequency pulse width modulated signal has one of at least two fixed frequencies corresponding to a desired magnetic heat effect.

18. The method according to claim 17, wherein each pulse width modulated signal is modulated through one of a plurality of active duty cycles corresponding to a desired duty cycle to achieve a level of inductive power to control heating of the electrically conductive and magnetic particles, the duty cycles being from 0-100%.

19. A system for inductive control heating of a polymer composition containing a polymer matrix material and electrically conductive and magnetic particles, comprising:

a high frequency power generator;

a high frequency match impedance tuner connected to the power generator;

a pulse width modulator connected to the power generator for modulating the generator output power;

a control unit for generating control signals that represent a desired time frequency and a desired duty cycle, the control signals being forwarded to the pulse width modulator and the power generator so as to produce fixed or variable frequency pulse width modulation signals that each have one of at least two fixed frequencies corresponding to a desired magnetic heat effect; and

a magnetic field work coil connected to the tuner so as to receive the fixed or variable frequency pulse width modulated signals and control magnetic field flux density of the work coil, whereby the work coil heats the polymer composition using the electrically conductive and magnetic particles.

20. The system according to claim 19, wherein the power generator, tuner and pulse width modulator form a high frequency power generator circuit that operates in a range of 80 KHz to 30 MHz.