Apparatus for oscillatory bonding of dissimilar thermoplastic materials

Claim 2

Apparatus for oscillatory friction welding a thermoplastic polymer component to a component made of a dissimilar material, said apparatus comprising: a first holder adapted for securing a first component to be welded, comprising first holding means and a first receptacle for receiving said first component; said first holder being mounted on a tool adapted for axial sliding movement; said tool being mounted on a carrier assembly; oscillator means connected to said first tool and said carrier assembly and arranged to oscillate said first tool axially with respect to said carrier assembly; a second holder secured to a spindle mount and adapted for holding a second article to be welded to said first article, said second holder being axially aligned with said first holder in close proximity thereto, and comprising a receptacle for receiving said second article; means for moving said first and second holders in axially reciprocating movement toward and away from each other; and an external heat generator mounted in close proximity to at least one of said holders and arranged to direct heat against a welding surface of a component held in said close proximity holder.

Claim 3

The apparatus of claim 1 wherein said holder in close proximity to said heat generator is further adapted to rotate about its vertical axis.

Claim 4

The apparatus of claim 2 further comprising means for rotating said holder in close proximity to said generator.

Claim 5

The apparatus of claim 1 wherein said heat generator is adapted to heat a circumferential surface.

Claim 6

The apparatus of claim 1 wherein said heat generator is selected from the group consisting of radiant heaters, jet heaters, radio frequency heaters, flame heaters, microwave heaters, and ultrasonic heaters.

Claim 7

The apparatus of claim 1 wherein said generator is a quartz heater.

Claim 8

The apparatus of claim 1 wherein said generator is an infrared light source.

Claim 9

The apparatus of claim 1 wherein said generator is a heated air jet.

Claim 10

An oscillatory bonding system for friction welding two thermoplastic polymer components made from dissimilar thermoplastic polymers, said system comprising: an upper mandrel for holding a first plastic component in vertical axial orientation; a lower mandrel for holding a second plastic component in vertical axial alignment with said first component; at least one of said mandrels being adapted for rapid oscillatory axial movement; at least one of said mandrels being adapted for substantial vertical displacement; means for axially displacing one of said mandrels; and, a heat generator for applying external heat to a plastic component held in one of said mandrels, said generator being arranged for placement in close proximity to one of said mandrels.

Claim 11

An oscillatory bonding system for friction welding two thermoplastic polymer components made from dissimilar thermoplastic polymers, said system comprising: an upper mandrel for holding a first plastic component in vertical axial orientation; a lower mandrel for holding a second plastic component in vertical axial alignment with said first component; at least one of said mandrels being adapted for rapid oscillatory axial movement; at least one of said mandrels being adapted for substantial vertical displacement; means for axially displacing one of said mandrels; and, a heat generator for applying external heat to a plastic component held in one of said mandrels, said generator being arranged for placement in close proximity to one of said mandrels.

Claim 12

The oscillatory bonding system of claim 9 wherein said mandrel in close proximity to said generator is further adapted for rotation about its vertical axis.

Claim 13

The oscillatory bonding system of claim 9 wherein said generator is adapted for circumferential movement around said mandrel.

Claim 14

The oscillatory bonding system of claim 9 wherein said heat generator is an integral part of one of said mandrels.

Claim 15

The oscillatory bonding system of claim 12 wherein said integral generator is directed substantially toward said other mandrel.

Claim 16

The oscillatory bonding system of claim 12 wherein said integral generator is directed toward the component area of said mandrel containing said generator.

Claim 17

The oscillatory bonding system of claim 9 wherein said heat generator comprises a heating element selected from the group consisting of infrared heaters, quartz heaters, electrical resistance heaters, radiant heaters, radio frequency heaters, microwave heaters, lasers, hot air jets, steam jets, flame heaters, and ultrasonic heaters.

Claim 18

A multi-station friction welding assembly for the oscillatory bonding together of at least two thermoplastic articles made of dissimilar plastics; said assembly having at least two bonding stations thereon and comprising: a stationary base portion; an upper assembly mounted on said base portion; a lower assembly mounted on said base portion below said upper assembly; said upper and lower assemblies adapted to maintain circumferential alignment with each other on said base portion; at least one of said upper and lower assemblies further adapted to be moved axially back-and-forth with respect to the other assembly on said base portion; means for moving at least one of said upper and lower assemblies axially back-and-forth with respect to the other; each said bonding station further comprising: a first holder slidably mounted on one of said upper and lower assemblies, adapted to receive and clamp a first thermoplastic article to be bonded; oscillating means on said first holder for oscillating said holder axially on said assembly; and, a second holder on the other of said upper and lower assemblies, axially aligned with said first holder, and adapted to receive and clamp a second thermoplastic article to be bonded to a first thermoplastic article; selective power means for supplying actuating power to said oscillating means and said holders at said bonding stations; heat generating means arranged for directing heat selectively towards at least one of said holders in each of said bonding stations; said moving means being adapted to move said first holder back-and-forth between a first position where said thermoplastic articles are separated and a second position where said thermoplastic articles are telescopically engaged with each other; said oscillating means being adapted to oscillate only when said first and second holders are in said article-engaged position, and said oscillating means further comprising frequency and amplitude adjusting means adapted to allow adjustment of the amplitude and frequency of said oscillating action to maintain said thermoplastic articles in telescopic engagement during oscillation thereof; and, said heat generating means being adapted to heat a circumferential portion of a component in one of said holders prior to said article-engaged position.

Claim 19

A multi-station friction welding assembly for the oscillatory bonding together of at least two thermoplastic articles made of dissimilar plastics; said assembly having at least two bonding stations thereon and comprising: a stationary base portion; an upper assembly mounted on said base portion; a lower assembly mounted on said base portion below said upper assembly; said upper and lower assemblies adapted to maintain circumferential alignment with each other on said base portion; at least one of said upper and lower assemblies further adapted to be moved axially back-and-forth with respect to the other assembly on said base portion; means for moving at least one of said upper and lower assemblies axially back-and-forth with respect to the other; each said bonding station further comprising: a first holder slidably mounted on one of said upper and lower assemblies, adapted to receive and clamp a first thermoplastic article to be bonded; oscillating means on said first holder for oscillating said holder axially on said assembly; and, a second holder on the other of said upper and lower assemblies, axially aligned with said first holder, and adapted to receive and clamp a second thermoplastic article to be bonded to a first thermoplastic article; selective power means for supplying actuating power to said oscillating means and said holders at said bonding stations; heat generating means arranged for directing heat selectively towards at least one of said holders in each of said bonding stations; said moving means being adapted to move said first holder back-and-forth between a first position where said thermoplastic articles are separated and a second position where said thermoplastic articles are telescopically engaged with each other; said oscillating means being adapted to oscillate only when said first and second holders are in said article-engaged position, and said oscillating means further comprising frequency and amplitude adjusting means adapted to allow adjustment of the amplitude and frequency of said oscillating action to maintain said thermoplastic articles in telescopic engagement during oscillation thereof; and, said heat generating means being adapted to heat a circumferential portion of a component in one of said holders prior to said article-engaged position.

Claim 20

The multi-station welding assembly of claim 16 wherein said heat generating means is fixedly mounted on said assembly and at least one of said holders in each said bonding station is further adapted to rotate about its vertical axis when passing in close proximity to said heat generating means.

Claim 21

The multi-station welding assembly of claim 16 wherein said heat generating means is located on at least one of said holders in each said bonding station.

Claim 22

The multi-station welding assembly of claim 16 wherein said heat generating means is movably mounted on said assembly and arranged for reciprocatory movement into and away from a position in close proximity to at least one of said holders.

Claim 23

The welding assembly of claim 19 wherein said heat generating means is further adapted for substantially encircling said holders.