METHOD OF LAMINATING ARTICLES

• US 20090008029A1
• Filed: 09/16/2008
• Published: 01/08/2009
• Est. Priority Date: 04/30/2004
• Status: Active Grant

• Current Assignee: Medtronic Incorporated (Medtronic Plc)
• Original Assignee: Medtronic Incorporated (Medtronic Plc)
• Inventors: Deininger, Steve T.
• Granted Patent: US 7,910,046 B2
• Time in Patent Office: Days
• US Class Current: 156/247
• CPC Class Codes: A61N 1/375 Constructional arrangements, e.g. casings
• CPC Class Codes: A61N 1/37512 Pacemakers
• CPC Class Codes: A61N 1/3787 from an external energy source
• CPC Class Codes: B29C 2045/0027 Gate or gate mark locations
• CPC Class Codes: B29C 45/0046 Details relating to the filling pattern or flow paths or flow characteristics of moulding material in the mould cavity
• CPC Class Codes: B29C 45/14836 Preventing damage of inserts during injection, e.g. collapse of hollow inserts, breakage B29C45/14434 takes precedence
• CPC Class Codes: B29C 63/02 using sheet or web-like material B29C63/26 and B29C63/38 take precedence
• CPC Class Codes: B29L 2031/7532 Artificial members, protheses
• CPC Class Codes: B32B 2037/264 Pressure equalizing layers
• CPC Class Codes: B32B 2535/00 Medical equipment, e.g. bandage, prostheses or catheter
• CPC Class Codes: B32B 37/26 with at least one layer which influences the bonding during the lamination process, e.g. release layers or pressure equalising layers
• CPC Class Codes: B32B 7/04 Interconnection of layers
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: Y10T 29/42 Piezoelectric device making

Abstract

A method of laminating a sheet or sheets to a substrate and a method of laminating a plurality of articles. The substrate is inserted into a press. The sheet is inserted into the press over the substrate. Liquid thermoset polymer is injected into the press. Heat and pressure are applied forcing the liquid thermoset polymer against the sheet and forcing the sheet against the substrate. The liquid thermoset polymer is allowed to cure under heat and pressure forming a cured silicone rubber sheet. The cured silicone rubber sheet is removed from the press. A plurality of articles may be laminated by laminating the second of the articles while the first article is cooling.

Claims

1. A method of laminating a first cover sheet to a first side of a substrate and simultaneously laminating a second cover sheet to a second side of said substrate, comprising the steps of:

inserting said substrate into a press;

inserting said first cover sheet into said press on said first side of said substrate;

inserting said second cover sheet into said press on second side of said substrate;

then injecting liquid thermoset polymer into said press on both sides of said substrate;

applying heat and pressure into said press forcing said liquid thermoset polymer against said first cover sheet and said second cover sheet and forcing said first cover sheet and said second cover sheet against said substrate;

allowing said liquid thermoset polymer to cure under heat and pressure forming a first cured silicone rubber sheet on said first side of said substrate and forming a second cured silicone rubber sheet on said second side of said substrate;

removing said substrate from said press; and

removing said first cured silicone rubber sheet and second cured silicon rubber sheet;

whereby said first cover sheet and second cover sheet are laminated to said substrate through the force of pressure from said liquid thermoset polymer.

2. A method of laminating as in claim 1 further comprising the step of applying an insulative sheet over each side of said substrate before inserting said substrate into said press.

3. A method of laminating as in claim 2 wherein said insulative sheet comprises a polymeric sheet.

4. A method of laminating as in claim 3 wherein said polymeric sheet comprises polyimide.

5. A method of laminating as in claim 1 wherein said first cover sheet and said second cover sheet have a layer of adhesive on one side thereof and wherein said first cover sheet and said second cover sheet are adhesively secured to said substrate.

6. A method of laminating as in claim 1 wherein said removing said first cured silicone rubber sheet step and said removing said second cured rubber sheet occur after said removing said substrate from said press step.

7. A method of laminating as in claim 1 further comprising the step of placing said first cover sheet and said second cover sheet over said substrate and wherein said inserting said substrate, said inserting said first cover sheet step and said inserting said second cover sheet steps occur simultaneously.

8. A method of laminating as in claim 1 further comprising the step of discarding said first cured silicone rubber sheet and said second cured silicone rubber sheet.

9. A method of laminating as in claim 1 further comprising the step of allowing said substrate to cool after said removing said substrate from said press step and before said removing said first cured silicone rubber sheet and said removing said second cured silicone rubber sheet steps.

10. A method of laminating as in claim 1 wherein said liquid thermoset polymer comprises liquid silicone rubber.

11. A method of forming a laminated coil assembly, comprising the steps of:

inserting a substrate having a coil positioned on a plurality of layers of magnetic material into a press;

inserting a first polymeric cover sheet into said press on said first side of said substrate;

inserting a second polymeric cover sheet into said press on second side of said substrate;

then injecting liquid thermoset polymer into said press on both sides of said substrate;

applying heat and pressure into said press forcing said liquid thermoset polymer against said first polymeric cover sheet and said second polymeric cover sheet and forcing said first polymeric cover sheet and said second polymeric cover sheet against said substrate;

allowing said liquid thermoset polymer to cure under heat and pressure forming a first cured silicone rubber sheet on said first side of said substrate and forming a second cured silicone rubber sheet on said second side of said substrate;

removing said substrate from said press; and

removing said first cured silicone rubber sheet and second cured silicon rubber sheet;

whereby said first polymeric cover sheet and second polymeric cover sheet are laminated to said substrate through the force of pressure from said thermoset polymer.

12. A method of laminating as in claim 11 further comprising the step of applying an insulative sheet over each side of said substrate before inserting said substrate into said press.

13. A method of laminating as in claim 12 wherein said insulative sheet comprises a polymeric sheet.

14. A method of laminating as in claim 13 wherein said polymeric sheet comprises polyimide.

15. A method of laminating as in claim 11 wherein said first polymeric cover sheet and said second polymeric cover sheet have a layer of adhesive on one side thereof and wherein said first polymeric cover sheet and said second polymeric cover sheet are adhesively secured to said substrate.

16. A method of laminating as in claim 11 wherein said removing said first cured silicone rubber sheet step and said removing said second cured rubber sheet occur after said removing said substrate from said press step.

17. A method of laminating as in claim 11 further comprising the step of placing said first polymeric cover sheet and said second polymeric cover sheet over said substrate and wherein said inserting said substrate, said inserting said first polymeric cover sheet step and said inserting said second polymeric cover sheet steps occur simultaneously.

18. A method of laminating as in claim 11 further comprising the step of discarding said first cured silicone rubber sheet and said second cured silicone rubber sheet.

19. A method of laminating as in claim 11 further comprising the step of allowing said substrate to cool after said removing said substrate from said press step and before said removing said first cured silicone rubber sheet and said removing said second cured silicone rubber sheet steps.

20. A method of laminating as in claim 11 wherein said liquid thermoset polymer comprises liquid silicone rubber.

21. A method of laminating a plurality of articles, each of said plurality of articles having a cover sheet laminated to a substrate, comprising the steps of:

inserting said substrate and said cover sheet of a first of said plurality of articles into a press;

injecting thermoset polymer into said press;

applying heat and pressure to said press forcing said thermoset polymer against said cover sheet and forcing said cover sheet against said substrate of said first of said plurality of articles;

allowing said thermoset polymer to cure under heat and pressure forming a cured silicone rubber sheet;

removing said substrate of said first of said plurality of articles from said press;

allowing said substrate of said first of said plurality of articles to cool;

inserting said substrate and said cover sheet of a second of said plurality of articles into a press, said inserting said substrate of said second of said plurality of articles step occurring during said allowing said substrate of said first of said plurality of articles to cool step;

injecting thermoset polymer into said press;

applying heat and pressure into said press forcing said thermoset polymer against said cover sheet and forcing said cover sheet against said substrate of said second of said plurality of articles;

allowing said thermoset polymer to cure under heat and pressure forming a cured silicone rubber sheet;

removing said substrate of said second of said plurality of articles from said press; and

removing said cured silicone rubber sheet from said substrate of said first of said plurality of articles while said substrate of said second of said plurality of articles is in said press;

whereby said cover sheet of said first of said plurality of articles is laminated to said substrate of said first of said plurality of articles through the force of pressure from said thermoset polymer; and

whereby said press may be utilized to laminate said second of said plurality of articles while said first of said plurality of articles is cooling.

22. A method of laminating as in claim 21 wherein said cover sheet of each of said plurality of articles has a layer of adhesive on one side thereof and wherein said cover sheet is adhesively secured to said substrate.

23. A method of laminating as in claim 21 wherein said removing said cured silicone rubber sheet step occurs after said removing said substrate from said press step.

24. A method of laminating as in claim 21 further comprising the step of placing said cover sheet over said substrate and wherein said inserting said substrate and said inserting said cover sheet steps occur simultaneously.

25. A method of laminating as in claim 21 further comprising the step of discarding said cured silicone rubber sheet.

26. A method of laminating as in claim 21 further comprising the step of allowing said substrate of said second of said plurality of articles to cool after said removing said substrate of said second of said plurality of articles from said press step and before said removing said cured silicone rubber sheet step.

27. A method of laminating as in claim 21 wherein said liquid thermoset polymer comprises liquid silicone rubber.