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

• US 7,984,738 B2
• Filed: 11/13/2007
• Issued: 07/26/2011
• 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
• Primary Examiner(s): Nguyen; Khanh
• Assistant Examiner(s): Patel; Vishal I
• Application Number:
  US11/983,961
• Publication Number:
  US 20090004466A1
• Time in Patent Office: 1,351 Days
• Field of Search: 156/366, 156/64, 156/272.2, 156/359, 156/379.6, 219/633, 524/439, 700/299, 700/300
• US Class Current: 156/359
• 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 method for controlled temperature bonding with a polymer composition comprising magnetic particles dispersed in a polymer matrix material, the method comprising the steps of:

generating electromagnetic induction energy having an electromagnetic induction energy frequency selected from the range of 80 kHz to 30 MHz;

pulse width modulating the electromagnetic induction energy to generate a first pulse width modulated electromagnetic energy having a pulse width modulation frequency and a first duty cycle selected from a plurality of duty cycles;

heating the polymer composition with the first pulse width modulated electromagnetic induction energy for a first heating interval;

pulse width modulating the electromagnetic induction energy to generate a second pulse width modulated electromagnetic induction energy having the pulse width modulation frequency and a second duty cycle selected from the plurality of duty cycles; and

heating the polymer composition with the second pulse width modulated electromagnetic induction energy for a second heating interval.

2. The method according to claim 1, wherein the polymer composition further comprises electrically conductive particles dispersed in the polymer matrix material.

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

4. The method according to claim 1, wherein the plurality of duty cycles range from 0-100%.

5. The method according to claim 1, further comprising the steps of:

disposing the polymer composition between a first component and a second component; and

fusing the first component to the second component with the polymer composition.

6. The method according to claim 5, wherein:

the first component comprises one of;

a first thermoplastic material; and

a first thermoset material; and

the second component comprises one of;

a second thermoplastic material; and

a second thermoset material.

7. The method of claim 1, wherein the first duty cycle and the second duty cycle are different.

8. The method of claim 1, wherein the first heating interval and the second heating interval are different.