Machine for welding hollow articles and process for welding these articles

• US 6,328,842 B1
• Filed: 07/15/1999
• Issued: 12/11/2001
• Est. Priority Date: 07/22/1998
• Status: Expired due to Fees

• Current Assignee: Inergy Automotive Systems Research (Societe Anonyme) (Solvac SA)
• Original Assignee: Solvay SA (Solvac SA)
• Inventors: Op De Beeck, Joel, Van Schaftingen, Jules-Joseph, Gilliard, Pierre, Van Meulebeke, Guy, Coninck, Hubert
• Primary Examiner(s): SELLS, JAMES D
• Application Number:
  US09/353,635
• Time in Patent Office: 880 Days
• Field of Search: 156/304.1, 156/304.2, 156/304.6, 156/308.2, 156/309.9, 156/498, 156/499
• US Class Current: 156/304.2
• CPC Class Codes: B29C 65/203 being several single mirrors, e.g. not mounted on the same tool
• CPC Class Codes: B29C 65/2061 by sliding
• CPC Class Codes: B29C 65/242 the heat transfer being achieved by contact, i.e. a heated tool being brought into contact with the welding tool and afterwards withdrawn from it
• CPC Class Codes: B29C 65/245 the heat transfer being achieved contactless, e.g. by radiation B29C65/32 takes precedence
• CPC Class Codes: B29C 65/26 Hot fluid
• CPC Class Codes: B29C 65/28 Flame or combustible material
• CPC Class Codes: B29C 65/30 Electrical means B29C65/38 takes precedence
• CPC Class Codes: B29C 65/32 Induction
• CPC Class Codes: B29C 65/7802 Positioning the parts to be joined, e.g. aligning, indexing or centring
• CPC Class Codes: B29C 65/7847 using vacuum to hold at least one of the parts to be joined vacuum work holders in general B25B11/005
• CPC Class Codes: B29C 65/7858 characterised by the feeding movement of the parts to be joined
• CPC Class Codes: B29C 66/0222 without removal of material, e.g. cleaning by air blowing or using brushes
• CPC Class Codes: B29C 66/0242 Heating, or preheating, e.g. drying B29C66/3464 takes precedence
• 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 66/54 Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
• 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 66/723 being multi-layered B29C66/7292, B29C66/72941 take precedence
• CPC Class Codes: B29C 66/80 General aspects of machine operations or constructions and parts thereof
• CPC Class Codes: B29C 66/81265 Surface properties, e.g. surface roughness or rugosity
• CPC Class Codes: B29C 66/8242 Pneumatic or hydraulic drives using fluid pressure directly acting on the parts to be joined B29C66/8266
• CPC Class Codes: B29C 66/83221 : cooperating reciprocating tools, each tool reciprocating along one axis
• CPC Class Codes: B29C 67/0048 : Local deformation of formed objects
• CPC Class Codes: B29K 2023/00 : Use of polyalkenes or derivatives thereof as moulding material
• CPC Class Codes: B29K 2061/00 : Use of condensation polymers of aldehydes or ketones or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2067/00 : Use of polyesters 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 2105/06 : containing reinforcements, fillers or inserts
• CPC Class Codes: B29K 2105/16 : Fillers
• CPC Class Codes: B29L 2009/00 : Layered products
• CPC Class Codes: B29L 2031/7172 : Fuel tanks, jerry cans

Abstract

Machine for welding hollow articles and process for welding these articles, for example half-shells of a plastic fuel tank, using the technique of hot-plate welding. A particular process in which the articles to be welded together are preshaped by pressing against a cold plate, which might not be plane, by stretching or compressing the side walls of the articles or by pressing against the walls of a mold. Process applied to the manufacturer of injection-molded/welded fuel tanks. Use of the machine for manufacturing such tanks.

Claims

1. Process for welding together edge to edge hollow plastic shells for producing a plastic fuel tank in a welding cycle in which;

a) at the start of the cycle, at least two shells to be welded together are positioned so as to present their weld lips face to face;

b) a cold plate, whose temperature is below that required to locally melt the plastic of the lips when they are in contact with the cold plate, is moved and brought between the weld lips of each shell which are face to face;

c) the shells are pressed against the two faces of the cold plate with a pressure and for a time necessary to deform the profile of the weld lips and to optimally adjust their correspondence;

d) the shells are moved away from the cold plate;

e) the cold plate is withdrawn;

f) a hot plate is moved and brought between the weld lips of each shell which are face to face, the temperature of the hot plate being high enough to be able to melt, by contact with it, the plastic to be welded;

g) the shells are pressed on the two faces of the hot plate for a time at least long enough to start to melt the shells on the surface of the lips in contact with the hot plate;

h) the shells are moved away from the hot plate;

i) the hot plate is withdrawn;

j) the shells are pressed against each other so as to bring the heated lips into contact for the time necessary for welding and for returning the molten material to the solid phase; and

k) the thus obtained assembly forming a plastic tank is removed.

2. Process according to claim 1, characterized in that the cold plate and the hot plate are one and the same plate comprising at least one cold region whose temperature does not allow the plastic to melt, and at least one hot region whose temperature is high enough to be able to melt the plastic with which the hot region can be brought into contact.

3. Process according to claim 1, characterized in that the plate is not planar.

4. Process according to claim 1, characterized in that the shaping continues by pressing the shells against the hot plate immediately before the welding operation.

5. Process according to claim 1, characterized in that, prior to being welded together, the hollow plastic shells are first obtained by an injection-moulding technique.

6. Machine for welding together edge to edge hollow plastic shells in order to produce at least one plastic fuel tank using the hotplate technique, comprising a hot plate and means for heating this plate, means for holding and positioning the shells to be welded together face to face so as to be able to bring the weld lips together, which weld lips correspond to the edge surface of each shell, means for moving the hot plate between the weld lips and means for pressing the shells against the hot plate, characterized in that said machine also comprises a cold plate whose temperature does not allow the plastic with which the cold plate may be brought into contact to melt.

7. Welding machine according to claim 6, characterized in that the hot plate and the cold plate are one and the same plate, comprising at least one hot zone and at least one cold zone.

8. Welding machine according to claim 6, characterized in that the plate is not planar.