Radio frequency (RF) heating system

• US 6,649,888 B2
• Filed: 10/25/2001
• Issued: 11/18/2003
• Est. Priority Date: 09/23/1999
• Status: Expired due to Term

• Current Assignee: Ambrell Corporation (inTEST Corporation)
• Original Assignee: Codaco, Inc.
• Inventors: Chiarilli, Francisco, Ryan, William J., Gorbold, Jonathan M., Adishian, Gary C.
• Primary Examiner(s): Van, Quang T.
• Application Number:
  US09/983,582
• Publication Number:
  US 20020079121A1
• Time in Patent Office: 754 Days
• Field of Search: 219/634, 219/660, 219/661, 219/663, 219/666, 219/764, 219/765, 219/770, 219/777, 219/778-780, 219/773, 156/272.4, 156/345, 156/274.8, 428/210, 438/729, 455/115, 330/302
• US Class Current: 219/634
• CPC Class Codes: B29C 65/00 Joining or sealing of preformed parts , e.g. welding of plastics materials; Apparatus therefor general aspects of processes or apparatus for joining preformed parts B29C66/00; using porous material formed by internal pressure generated therein for joining preformed parts B29C44/1228, B29C44/326
• CPC Class Codes: B29C 65/3644 being a ribbon, band or strip
• CPC Class Codes: B29C 65/3656 being a layer of a multilayer part to be joined, e.g. for joining plastic-metal laminates
• CPC Class Codes: B29C 65/3676 being metallic
• CPC Class Codes: B29C 65/368 with a polymer coating
• CPC Class Codes: B29C 65/3684 being non-metallic
• CPC Class Codes: B29C 65/3696 with a coating
• CPC Class Codes: B29C 66/0044 using a separating sheet, e.g. fixed on the joining tool
• CPC Class Codes: B29C 66/112 Single lapped joints
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/114 Single butt joints
• CPC Class Codes: B29C 66/1222 comprising at least a lapped joint-segment
• CPC Class Codes: B29C 66/1224 comprising at least a butt joint-segment
• CPC Class Codes: B29C 66/12425 Other specific interlocking undercuts not provided for in B29C66/12421 - B29C66/12423
• CPC Class Codes: B29C 66/12445 having the tongue on the side
• CPC Class Codes: B29C 66/12821 comprising at least two overlap joint-segments
• CPC Class Codes: B29C 66/1284 comprising at least one butt joint-segment
• CPC Class Codes: B29C 66/43 Joining a relatively small portion of the surface of said articles B29C66/45 takes precedence
• CPC Class Codes: B29C 66/431 Joining the articles to themselves B29C66/4322 and B29C66/4332 take precedence
• CPC Class Codes: B29C 66/45 Joining of substantially the whole surface of the articles methods or apparatus for laminating B32B37/00
• CPC Class Codes: B29C 66/472 : said single elements being substantially flat
• CPC Class Codes: B29C 66/53461 : joining substantially flat covers and/or substantially flat bottoms to open ends of container bodies
• CPC Class Codes: B29C 66/542 : joining hollow covers or hollow bottoms to open ends of container bodies
• 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 66/72328 : Paper
• CPC Class Codes: B29C 66/7234 : comprising a barrier layer
• CPC Class Codes: B29C 66/73921 : characterised by the materials of both parts being thermoplastics
• CPC Class Codes: B29C 66/8122 : characterised by the composition of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
• CPC Class Codes: B29C 66/81263 : Dielectric properties
• CPC Class Codes: B29C 66/81871 : of the welding jaws
• CPC Class Codes: B29C 66/8322 : Joining or pressing tools reciprocating along one axis
• CPC Class Codes: B29C 66/83221 : cooperating reciprocating tools, each tool reciprocating along one axis
• CPC Class Codes: B29C 66/83413 : cooperating rollers, cylinders or drums
• CPC Class Codes: B29C 66/836 : Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table B29C66/65 takes precedence
• CPC Class Codes: B29K 2001/00 : Use of cellulose, modified cellulose or cellulose derivatives, e.g. viscose, as moulding material
• CPC Class Codes: B29K 2021/00 : Use of unspecified rubbers as moulding material
• CPC Class Codes: B29K 2023/00 : Use of polyalkenes or derivatives thereof as moulding material
• CPC Class Codes: B29K 2023/06 : PE, i.e. polyethylene
• CPC Class Codes: B29K 2023/083 : EVA, i.e. ethylene vinyl acetate copolymer
• 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 2025/06 : PS, i.e. polystyrene
• CPC Class Codes: B29K 2027/06 : PVC, i.e. polyvinylchloride
• CPC Class Codes: B29K 2029/04 : PVOH, i.e. polyvinyl alcohol B29K2031/04 takes precedence
• CPC Class Codes: B29K 2033/08 : Polymers of acrylic acid esters, e.g. PMA, i.e. polymethylacrylate
• CPC Class Codes: B29K 2067/00 : Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2067/046 : PLA, i.e. polylactic acid or polylactide
• 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 2827/18 : PTFE, i.e. polytetrafluorethene, e.g. ePTFE, i.e. expanded polytetrafluorethene
• CPC Class Codes: C08L 67/00 : Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain of polyester-amides C08L77/12; of polyester-imides C08L79/08; Compositions of derivatives of such polymers
• CPC Class Codes: C09D 167/00 : Coating compositions based on polyesters obtained by reactions forming a carboxylic ester link in the main chain based on polyester-amides C09D177/12; based on polyester-imides C09D179/08; Coating compositions based on derivatives of such polymers
• CPC Class Codes: C09J 167/00 : Adhesives based on polyesters obtained by reactions forming a carboxylic ester link in the main chain based on polyester-amides C09J177/12; based on polyester-imides C09J179/08; Adhesives based on derivatives of such polymers
• CPC Class Codes: C09J 2467/00 : Presence of polyester
• CPC Class Codes: C09J 5/04 : involving separate application of adhesive ingredients to the different surfaces to be joined
• CPC Class Codes: C09J 5/06 : involving heating of the applied adhesive
• CPC Class Codes: Y10T 428/31551 : Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]

Abstract

An RF heating system for bonding a first element to a second element. In one embodiment, the RF heating system includes: (a) a composition, which functions as an adhesive, interposed between the first and second elements, the composition including an ionomer and a polar carrier, wherein the ionomer and/or the carrier are present in amounts effective to allow the composition to be headed by a fringe RF field; and (b) a radio frequency (RF) heating apparatus for producing the fringe RF field.

Claims

1. A system for bonding or adhering a first substrate to a second substrate, comprising:

a susceptor composition interposed between the first and second substrates, said composition comprising one or more ionomers and one or more polar carriers, wherein said polar carrier(s) comprise about 13 to about 25 weight percent of the composition with respect to the combined weight of the polar carrier(s) and the ionomer(s); and

a radio frequency (RF) heating system for producing a fringe RF field that is used to heat the composition, said RF heating apparatus comprising;

a power supply; and

an RF energy applicator electrically coupled to said power supply, wherein

said RF energy applicator comprises a first elongated electrode and a second elongated electrode, wherein a first end of said first elongated electrode is electrically connected to said power supply and a first end of said second elongated electrode is electrically connected to said power supply, wherein said first and second elongated electrodes are used to create said fringe RF field.

2. The system of claim 1, wherein said first elongated electrode and said second elongated electrode are positioned such at least a first portion of the first elongated electrode is substantially parallel with a first portion of the second elongated electrode.

3. The system of claim 2, wherein a second portion of the first electrode is angled in a direction away from the second electrode, said second portion of the first electrode being between said first portion and an end of the first electrode, and a second portion of the second electrode is angled in a direction away from the first electrode, said second portion of the second electrode being between said first portion and an end of the second electrode.

4. The system of claim 2, wherein a distal end of the first electrode is bent away from the second electrode and a distal end of the second electrode is bent away from the first electrode.

5. The system of claim 1, wherein said composition is placed in a region adjacent to the space between the elongated electrodes when it is desired to heat the composition using said fringe field so that said composition is exposed to said fringe field.

6. The system of claim 5, further comprising a low dielectric material, the material covering at least a portion of the first electrode and at least a portion of the second electrode so that when the composition is placed in the region the material is between the electrodes and the composition.

7. The system of claim 1, wherein the one or more ionomer(s) and the one or more polar carriers are substantially blended with one another and form a mixture.

8. The system of claim 1, wherein the ionomer and the polar carrier are disposed on one another.

9. The system of claim 1, wherein The polar carrier has a dielectric constant of 13-63 (25°

C.).

10. The system of claim 1, comprising one ionomer and one polar carrier.

11. The system of claim 1, wherein said one or more ionomer(s) is a sulfonated polyester.

12. The system of claim 11, wherein said sulfonated polyester is the salt of a sulfonated polyester.

13. The system of claim 11, wherein the sulfonated polyester is a linear polyester with a high Tg.

14. The system of claim 1, wherein said one or more ionomer(s) is an acrylic acid copolymer, or a salt thereof.

15. The system of claim 1, wherein said one or more ionomer(s) is a protein.

16. The system of claim 15, wherein said protein is gelatin.

17. The system of claim 16, wherein said gelatin has a pH of about 8 to 12.

18. The system of claim 16, wherein said gelatin has a pH of about 1 to about 6.

19. The system of to claim 1, wherein said one or more polar carrier(s) is a polyol.

20. The system of claim 1, wherein said RF energy applicator further comprises an electrically conductive coil, wherein said coil is connected between said first and said second elongated electrodes.

21. The system of claim 1, wherein each of the first and second elongated electrodes is a conductive tube.

22. The system of claim 1, wherein the first electrode has a diameter or width between about one-eighth of an inch and one-half of an inch.

23. The system of claim 1, wherein said power supply comprises an amplifier and an impedance matching circuit connected to an output of said amplifier, the amplifier being operable to amplify a radio frequency (RF) signal.

24. The system of claim 23, wherein the impedance matching circuit comprises an inductor, and the first electrode, the second electrode, and the inductor are connected in series such that the inductor is connected between the first electrode and the second electrode.

25. The system of claim 1, wherein said elongated electrodes include a portion that is curvilinear.

26. The system of claim 25, wherein said curvilinear portion is sinusoidally shaped.

27. A system for bonding or adhering a first substrate to a second substrate, comprising:

a susceptor composition interposed between the first and second substrates, said composition comprising one or more ionomers and one or more polar carriers, wherein said polar carrier(s) comprise about 13 to about 25 weight percent of the composition with respect to the combined weight of the polar carrier(s) and the ionomer(s); and

a radio frequency (RF) heating system for producing a fringe RF field that is used to heat the composition, said RF heating system comprising;

a power supply; and

an RF energy applicator electrically coupled to said power supply, wherein

said RF energy applicator comprises a first elongated electrode, a second elongated electrode, a first electrically conductive coil, and a second electrically conductive coil;

a first connector connects said power supply to a point on said first elongated electrode that is midway or about midway between the ends of said first elongated electrode,

a second connector connects said power supply to a point on said second elongated electrode that is midway or about midway between the ends of said second elongated electrode, and

said first coil and said second coil are connected in parallel by said first and second elongated electrodes, wherein said first and second elongated electrodes are used to create said fringe RF field.

28. The system of claim 27, wherein said first elongated electrode and said second elongated electrode are positioned such at least a first portion of the first elongated electrode is substantially parallel with a first portion of the second elongated electrode.

29. The system of claim 27, wherein said composition is placed in a region adjacent to the space between the elongated electrodes when it is desired to heat the composition using said fringe field so that said composition is exposed to said fringe field.

30. The system of claim 29, further comprising a low dielectric material, the material covering the first and second electrode so that when the composition is placed in the region the material is between the electrodes and the composition.

31. The system of claim 27, wherein the one or more ionomer(s) and the one or more polar carriers are substantially blended with one another and form a mixture.

32. The system of claim 27, wherein the ionomer and the polar carrier are disposed on one another.

33. The system of claim 27, wherein the polar carrier has a dielectric constant of 13-63 (25°

C.).

34. The system of claim 27, comprising one ionomer and one polar carrier.

35. The system of claim 27, wherein said one or more ionomer(s) is a sulfonated polyester.

36. The system of claim 35, wherein said sulfonated polyester is the salt of a sulfonated polyester.

37. The system of claim 35, wherein the sulfonated polyester is a linear polyester with a high Tg.

38. The system of claim 27, wherein said one or more ionomer(s) is an acrylic acid copolymer, or a salt thereof.

39. The system of claim 27, wherein said one or more ionomer(s) is a protein.

40. The system of claim 39, wherein said protein is gelatin.

41. The system of claim 40, wherein said gelatin has a pH of about 8 to 12.

42. The system of claim 40, wherein said gelatin has a pH of about 1 to about 6.

43. The system of to claim 27, wherein said one or more polar carrier(s) is a polyol.

44. The system of claim 27, wherein said power supply comprises an amplifier and an impedance matching circuit connected to an output of said amplifier, the amplifier being operable to amplify a radio frequency (RF) signal.

45. The system of claim 27, wherein each of the first and second elongated electrodes is a conductive tube.

46. The system of claim 27, wherein the first electrode has a diameter or width between about one-eighth of an inch and one-half of an inch.