Method and apparatus for thermoplastic film welding

A system for producing a continuous seam between a first thermoplastic film and a second thermoplastic film, comprising:

• a heating and compaction device configured to produce a bonding between an edge portion of the first thermoplastic film and an edge portion of the second thermoplastic film, and configured to apply a compaction force against the edge portion of the first thermoplastic film and the edge portion of the second thermoplastic film;
• a joining process interface (JPI) layer configured to be disposed adjacent to a surface of at least one of the edge portion of the first thermoplastic film or the edge portion of the second thermoplastic film, and between the heating and compaction device and the edge portion of the first thermoplastic film and the edge portion of the second thermoplastic film;
• and
• a system controller in communication with the heating and compaction device and a non-transitory memory storing instructions, which instructions when executed cause the system controller to:
• control the heating and compaction device to produce the bonding between the edge portion of the first thermoplastic film and an edge portion of the second thermoplastic film;
• control the heating and compaction device to apply the compaction force against the edge portion of the first thermoplastic film and the edge portion of the second thermoplastic film;
• control movement of at least the one of the heating and compaction device and the first thermoplastic film and second thermoplastic film relative to one another to produce a continuous seam between the first thermoplastic film and second thermoplastic film;
• and
• wherein the JPI layer is maintained stationary relative to the first thermoplastic film and second thermoplastic film.

A method of producing a continuous seam between a first thermoplastic film and a second thermoplastic film, comprising:

• disposing an edge portion of the first thermoplastic film adjacent to an edge portion of the second thermoplastic film;
• and
• using a heating and compaction device to produce a bonding between at least a portion of the edge portion of the first thermoplastic film and the edge portion of the second thermoplastic film, and using the heating and compaction device to apply a compaction force against the edge portion of the first thermoplastic film and the edge portion of the second thermoplastic film;
• wherein a joining process interface (JPI) layer is applied to a surface of the heating and compaction device so as to be disposed between the heating and compaction device and the edge portion of the first thermoplastic film and the edge portion of the second thermoplastic film;
• and
• wherein at least the one of the heating and compaction device and the first thermoplastic film and second thermoplastic film are moved relative to the other to produce a continuous seam between the first thermoplastic film and second thermoplastic film.