Method of adhesive bonding by induction heating
First Claim
1. A method of adhesive bonding by induction heating, comprising:
- providing at least two substrates to be bonded;
providing a susceptor structure therebetween, said susceptor structure having a length, width, and thickness, said structure including at least one layer of an electrically conductive material, said structure including at least one layer of an adhesive material proximal to at least one of its outer surfaces, said structure being of a first characteristic by which said at least one layer of electrically conductive material generates an eddy current when exposed to a magnetic field of a predetermined minimum intensity, and said structure being of a second characteristic by which said at least one layer of electrically conductive material exhibits a thickness in the range of 0.01 mils (0.25 microns) through 3 mils (76 microns); and
exposing said susceptor structure to a magnetic field during a heating event for a time interval in the range of 0.05-10 seconds, inclusive, and at an average power density in the range of 10-5000 Watts per square inch of susceptor area, inclusive.
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Accused Products
Abstract
An apparatus and system for using magnetic fields to heat magnetically susceptible materials within and/or adjacent to adhesives, resins, or composites so as to reversibly or irreversibly bond, bind, or fasten opaque or non-opaque solid materials to one another. The system makes use of the effect that alternating magnetic fields induce eddy currents and generate heat within susceptors, and the effect that alternating magnetic fields additionally induce magnetic hysteresis that occurs in magnetic materials and thereby generate heat. An induction heating tool is used to emit the magnetic field at its work coil, and an electronic controller measures the energy being used by a power converter that generates the alternating current driving the work coil which creates the magnetic field. The distance between the susceptor and work coil is repeatedly analyzed based upon the power converter'"'"'s input energy, and the work coil is driven at a repeatedly corrected power level during the heating cycle. Once a sufficient accumulated energy has been delivered to the susceptor, the magnetic field is turned off automatically by the tool, thus preventing overheating of the susceptor.
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Citations
28 Claims
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1. A method of adhesive bonding by induction heating, comprising:
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providing at least two substrates to be bonded;
providing a susceptor structure therebetween, said susceptor structure having a length, width, and thickness, said structure including at least one layer of an electrically conductive material, said structure including at least one layer of an adhesive material proximal to at least one of its outer surfaces, said structure being of a first characteristic by which said at least one layer of electrically conductive material generates an eddy current when exposed to a magnetic field of a predetermined minimum intensity, and said structure being of a second characteristic by which said at least one layer of electrically conductive material exhibits a thickness in the range of 0.01 mils (0.25 microns) through 3 mils (76 microns); and
exposing said susceptor structure to a magnetic field during a heating event for a time interval in the range of 0.05-10 seconds, inclusive, and at an average power density in the range of 10-5000 Watts per square inch of susceptor area, inclusive. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15)
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16. A method of adhesive bonding by induction heating, comprising:
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providing at least two substrates to be bonded;
providing a susceptor structure therebetween, said susceptor structure having a length, width, and thickness, said structure including at least one layer of an electrically conductive material, said structure including at least one layer of an adhesive material proximal to at least one of its outer surfaces, said structure being of a first physical characteristic by which said at least one layer of electrically conductive material generates an eddy current when exposed to a magnetic field of a predetermined minimum intensity, and said structure being of a second physical characteristic by which said at least one layer of electrically conductive material exhibits a thickness in the range of 0.01 mils (0.25 microns) through 3 mils (76 microns); and
exposing said susceptor structure to a magnetic field during a heating event for a time interval in the range of 0.05-10 seconds, inclusive, and at an average power density in the range of 10-5000 Watts per square inch of susceptor area, inclusive.
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17. A method of adhesive bonding by induction heating, comprising:
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providing at least two substrates to be bonded;
providing a susceptor structure therebetween, said susceptor structure having a length, width, and thickness, said structure including at least one layer of an electrically conductive material, said structure including at least one layer of an adhesive material proximal to at least one of its outer surfaces, said structure being of a first characteristic by which said at least one layer of electrically conductive material generates an eddy current when exposed to a magnetic field of a predetermined minimum intensity, and said structure being of a second characteristic by which said at least one layer of electrically conductive material exhibits a thickness in the range of 0.01 mils (0.25 microns) through 3 mils (76 microns); and
exposing said susceptor structure to a magnetic field during a heating event for a time interval in the range of 0.05-10 seconds, inclusive. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28)
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Specification