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US 12,617,160 B2Granted
Variable frequency microwave joining
AssigneeMagna Exteriors Inc.
InventorsMarek Pospisek, Zdenek Severa
Life of this patent
Estimating the term…
Abstract
Bonded untreated plastic substrates and process for manufacturing same, including a variable frequency microwave and variable frequency microwave active welding paste. Use of 1-component variable frequency microwave cured paste adapted to wet and bond untreated plastic substrates that is operable to reduce production cycle time, reduce production costs, reduce operating costs, and reduce production line space. Hardening of the welding paste allows joining of thermoplastic panels quickly without the need for panel surface treatment. Polypropylene substrate bonding with 1-component epoxy adhesive that is variable frequency microwave reactive, wherein the substrates are untreated.
Claims19
A substrate adapted for a vehicle, comprising:
- a first panel formed of a first plastic material;
- a second panel formed of the first plastic material or a second plastic material that is different than the first plastic material, said first and second panels are untreated at a plurality of joining areas;
- and
- a predetermined 1-component VFM reactive welding paste located on said joining areas and hardened by VFM to thereby join said first and second panels together;
- multiple ribs on each of said first and second panels, the ribs extend outwardly from the first and second panels and are operable to allow VFM curing of the welding paste faster, a first rib plane of said ribs on said first panel is spaced from a second rib plane of said ribs on said second panel such that the ribs of said first panel do not overlap the ribs of said second panel along said first and second rib planes and said 1-component VFM reactive welding paste is located between said first and second rib planes and between respective adjacent ribs along said first and second panels.
2 more elements
A method of bonding substrates adapted for a vehicle, comprising:
- providing a Variable Frequency Microwave (VFM) machine;
- providing a first plastic material for forming a first panel;
- providing material for forming a second panel, where the material for forming the second panel is the same as the first plastic material or is a second plastic material that is different than the first plastic material;
- providing a 1-component epoxy VFM cured welding paste;
- forming the first and second panels with a ribs formed on both of the first panel and the second panel, said ribs operable to help to weld said first and second panels with said welding paste faster and with predetermined higher force;
- applying the welding paste in at least one location on the first panel and/or second panel where a joining of the first and second panels is desired;
- aligning the first and second panels with the welding paste in contact with said first and second panels, wherein a first rib plane of said ribs on said first panel is spaced from a second rib plane of said ribs on said second panel such that said first panel ribs do not overlap said second panel ribs along said first and second rib planes and said 1-component VFM cured welding paste is located between said first and second rib planes and between respective adjacent ribs along said first and second panels;
- and
- applying predetermined VFM (microwaves) to achieve a predetermined temperature to harden the welding paste to join the first and second panels.
6 more elements
A method of bonding substrates adapted for a vehicle, comprising:
- providing at least one first panel formed of a first plastic material and including at least one untreated joint area that includes attachment features in the form of ribs extending outwardly from an inner surface of the at least one first panel;
- providing at least one second panel formed of the first plastic material or other a plastic material and including at least one untreated joint area that includes attachment features in the form of ribs projecting outwardly from an inner surface of the at least one second panel;
- providing a VFM reactive welding paste;
- applying the welding paste in at least one untreated joint area on the first panel and/or second panel operable for joining the first and second panels;
- aligning the first and second panels with the welding paste in contact with said first and second panels and holding in contact, wherein a first attachment feature plane of said attachment features on said first panel is spaced from a second attachment feature plane of said attachment features on said second panel such that said first panel attachment features do not overlap said second panel attachment features along said first and second attachment feature planes and said VFM reactive welding paste is located between said first and second attachment feature planes and between respective adjacent attachment features along said first and second panels;
- applying predetermined VFM (microwaves) to achieve a predetermined temperature to harden the welding paste to join the first and second panels.
3 more elements
Dependencies are inferred from the claim text.