A METHOD OF WELDING AN EMBOSSING AND/OR WELDING AND/OR PARTING SEAM IN ONE OR MORE LAYERS OF MATERIAL CONTAINING HEAT-WELDABLE, ESPECIALLY THERMOPLASTIC PLASTIC MATERIAL, AND A WELDING PRESS FOR CARRYING OUT THE METHOD

Abstract: By the welding of plastic material, said plastic material is placed between a welding electrode (9) of a profile and pattern mating the welding to be performed, and a counter electrode (10) comprising one or several pulse heating wires (22). Together the pulse heating wires cover the pattern of the welding electrode (9) and project preferably a short distance beyond said welding electrode. The pulse heating wires are furthermore mutually and outwardly electrically insulated. A separating tape of a higher melting point than the plastic material has been inserted between the pulse heating wires (22) and the plastic material. The used welding press comprises a welding plane with the welding electrode (9) and a fixing plane (32) for the counter electrode (10). The temperature of the welding electrode (9) can be kept constant and within a temperature range of approximately 20 DEG C to approximately 250 DEG C. The fixing plane (32) is non-heated. The pulse heating wires (22) are secured to the fixing plane and are mutually and outwardly electrically insulated. Each pulse heating wire (22) communicates with a current source and an electronic regulator capable of setting and regulating the temperature and heating period of each pulse heating wire (22) very accurately.

Description: Title: A Method of Welding an Embossing and/or Welding and/or Parting Seam in one or more Layers of Material Containing Heat— eldable. Especially Thermoplastic Plastic Material, and a Welding Press for Carrying Out the Method Technical Field The invention relates to a method of welding an embos¬ sing and/or welding and/or parting seam in one or more layers of material containing heat-weldable, especially thermoplastic plastic material, by means of indirect heating of the pl-astics in a welding press. The invention relates furthermore to a welding press for carrying out the method and comprising a welding plane and a fixing plane, where the welding plane is provided with a welding electrode of a welding profile and pat- tern mating the welding to be carried out and the tem¬ perature of which can be kept constant within a temper¬ ature range of approximately 20 C C and approximately 250"C, and where at least one plane can be moved towards and away from the other plane. Background Art Heat contact welding is traditionally used for embos¬ sing, welding, cutting, and producing of bending lines in thermoplastic material, said welding involving a di- rect or an indirect heating or an HF-welding when it is a question of welding plastic materials presenting a sufficiently high dielectric loss, such as in case of PVC. The HF-welding is advantageous in only using a single electrode, i.e. the welding electrode, whereas the heat¬ ing of the material is caused by the dielectric losses in the material with the result that the method is ve^y easy and convenient to perform and does not require a production of exactly mating and accordingly expensive electrodes. The HF—generator of the machine is, however, very expensive and involves a high consumption of ener— gy. The method has gradually been extensively used espe¬ cially for welding PVC. A heat contact welding involving an indirect heating of the plastics employs usually a welding electrode and a counter electrode, where both electrodes are heated, the welding electrode being heated to a temperature about the softening temperature of the plastics and the count¬ er electrode being heated to a temperature exceeding the melting temperature of the plastics . The welding elec¬ trode includes the particular welding profile acting di— rectly on the possibly Teflon—coated top side of the plastics, whereas the counter electrode is plane and shielded from the plastics by means of a separation tape of a higher melting point than the plastics. The latter method has been extensively used for welding thin sheets, but can only be used to a limited extent for welding thick sheets and materials because the heat must be conducted through the plastics in order to reach the welding spot, and accordingly the top side of the plast¬ ics is heated more than the welding spot, which causes problems of heat damages of the plastics outside the welding seams. In order to obtain high production rates, attempts have been made at operating at temperatures being as high as possible, but such procedures only made the situation worse because the high temperatures and high amounts of heat, especially in the bottom tool, involved a considerably increased risk of the sheets being damaged. A consequence of the unintended heating is that the sheets turn sof and form bulges , especially in connection with even very short breaks . Attempts have been made at solving this problem by establishing suit¬ able screening devices and cooling devices , but these devices did not provide satisfactory results when thick sheets were involved. The above problems have become particularly topical be¬ cause of the present requirements for restricting the use of PVC so as to reduce the environmental damages. Accordingly, a demand has arisen for using other types of plastics, especially polyolefines . These types of plastics cannot, however, like PVC be welded by way of HF-welding in a satisfactory manner, and accordingly it is necessary to use heat-contact welding although such a welding does not provide satisfactory results. The problem applies in particular to the use of polyole- fines for the manufacture of thick-walled products, such as loose-leaf binders or more composite products, such as various wrappers comprising a varying number of lay- ers of material and consequently of a varying thickness on various locations of the product. In particular the use of polypropylene causes problems because said ma¬ terial presents a very narrow temperature range (ap¬ proximately 8"C) for being weldable. Pulse heat welding has furthermore been used within the packing industry, especially for the manufacture of bags, where the heating is carried out by means of elec¬ trically heated resistance wires. This method is, howev¬ er, only used for thin sheets, and as far as the appear- ance is concerned the quality of the weldings has been very poor compared to the requirements that can be met by HF-welding PVC. For a long time the opening of various types of packing made of heat-weldable sheet material of a thickness of approximately 50 to 100 μm has furthermore been a grow¬ ing source of irritation to the users , because it is almost impossible to open such packings by means of the fingers alone. The latter problem applies to a wide range of packed articles including building materials, feedstuff and fertilizers, furniture, tools, household articles, clothes, toys, gift articles, food, stimulants etc. It is often necessary to use tools, such as scis¬ sors or knives, with the result that injuries easily arise to the packed article or the user. It has not pre¬ viously been possible to provide a satisfactory solution of this problem by the known welding methods . Description of the Invention The object of the present invention is accordingly to provide an improved method and an associated apparatus for heat contact welding especially of thick plastic materials including polyolefines , where the resulting weldings as far as the appearance is concerned fully meet the results presented by HF— elding of PVC, and which in addition can be used for the manufacture of packings with airtight separation lines , which are suf¬ ficiently strong in use of the packing, but which allow an easy opening of the packing by the user without ne¬ cessitating the use of tools. The new and characteristic features of the method ac¬ cording to the invention are found in — using a combination of — a welding electrode arranged against one side of the material, said welding electrode in particular being an upper electrode of a welding profile and pattern mating the welding to be performed, — and a counter electrode of a corresponding pattern and arranged against the other side of the material and formed by one or several pulse heating wires, which are mutually and outwardly electrically in¬ sulated and cover the welding electrode and pre¬ ferably project a short distance beyond said welding electrode, where the pulse heating wire(s) is(are) secured to a preferably non-heated fixing plane, especially a water-cooled fixing plane, such as a bottom plane, and where each pulse heating wire com- municates with a current source and an electronic regulator, - as well as a heat-conducting separating tape ar¬ ranged between the pulse heating wire(s) and the material and being of a higher melting point than the plastic material, especially in form of a con¬ veyor belt for the material, - whereby the temperature of the welding electrode is kept constant and preferably below the softening point of the plastic material, - and where a current is shortly transmitted through the pulse heating wire(s) during the welding imme¬ diately before or after the welding press has been completely closed with the result that said wire(s) are heated and emit heat to the material, the elec- tronic regulator being set such that a very accu¬ rately controlled temperature is kept in the pulse heating wire(s) in a temperature range immediately above the melting point of the plastic material in question, and for a predetermined period being suf- ficiently long for ensuring the desired result, - whereafter the current through the pulse heating wire(s) is interrupted, the press is opened, and the material is immediately cooled on the cold fixing plane before fresh material is advanced for welding. In this manner it turned out surprisingly to be possible to carry out weldings of an even very high quality in all types of heat-weldable material. Most advantageously the welding is carried out at temperatures lower than the temperatures conventionally used by heat welding with indirect heating by means of conventional brass electrodes both for the welding electrodes and for the counter electrode. Thus extremely good results were for instance obtained by welding polypropylene at tempera¬ tures of 120 β C for the welding electrode and 170 β C for the pulse heating wire, respectively, where the conven¬ tional welding of polypropylene typically uses temper¬ atures of 130 β C for the welding electrode and 230 β C for the counter electrode, respectively. Although the method according to the invention thus operates at temperatures lower than the conventional temperatures , especially as far as the counter electrode is concerned, quite accept¬ able welding speeds are nevertheless obtained with the result that the method according to the invention can also compete with respect to the expenditure of time. The combination of the low temperatures and the very low amounts of energy used in the pulse heating wires rela¬ tive to the amounts of energy used In the conventional counter electrodes of brass eliminates furthermore com¬ pletely the previously known problems of heat damages of the plastic material within and outside the weldings in form of shrinkings or formation of bulges . Another fac¬ tor assisting in overcoming the latter problem is that the pulse heating wires are only heated in the very short period during which the welding is performed, whereafter the current is interrupted and the excess heat is then very quickly carried away by the cold fix¬ ing plane. Accordingly, the method is not encumbered with problems of breaks which might involve damaging heat effects on the plastic material. The energy con¬ sumption for the welding is low, and accordingly con¬ siderable amounts of energy are saved relative to the energy consumption of the conventional heat contact welding and HF-welding. In addition, the initial heating period of the welding press has been limited to the pe¬ riod necessary for heating the welding electrode to the relatively low temperature. Furthermore, no narrow re— strictions apply to the method according to the inven¬ tion with respect to the length of the weldings to be performed, whereas the conventional heat contact welding usually cannot perform weldings of a length exceeding approximately 700 mm due to the difficulties and costs involved in the production of counter electrodes , which in long lengths are sufficiently accurate at the high temperatures. Yet another advantage of the method ac¬ cording to the invention is that it turned out s rpris- ingly that the method allows a welding through materials being substantially thicker than it was previously con¬ sidered possible by the heat contact welding, and while still maintaining the outstanding quality of the welding seam. So far tests have proved that it is possible with- out problems to weld total sheet thicknesses of at least 3000 μm with a good result and merely by prolonging the welding period, where the upper limit of the convention¬ al heat contact welding was considered to be about 600 μm total sheet thickness before the welding. Various modifications of the method for many purposes can be obtained by using welding and counter electrodes presenting an annular welding pattern. Such a modifica¬ tion can for instance advantageously be used for produc¬ ing many articles welded from a large plastic material, by welding annular members therein, and furthermore for producing separating lines in a packing so as to allow an easy opening thereof. By the expression "annular welding pattern" is in this connection meant any pattern including a substantially coherent, circumferential welding/parting/embossing seam surrounding a non-welded area. Although the method according to the invention can be performed on a welding press without a depth stop for a number of purposes , such as when weld cuttings are to be performed, where the welding electrode therefore must penetrate the material completely, it can be advan- tageous or necessary for other purposes to use a welding press with a depth stop with a high setting accuracy so as during the welding to ensure a minimum distance be¬ tween the welding electrode and the counter electrode with the associated insulating layers, and to set the depth stop to a minimum distance corresponding to or being smaller than the total thickness of the material between the electrodes . The latter applies for instance to the production of packings with airtight separating lines facilitating an opening later on of the packing, and then the depth stop is advantageously set to a minimum distance between the electrodes corresponding to an interval of approximately 20% and approximately 80%, especially between approxi- mately 30% and approximately 70%, of the thickness of the material between the electrodes. Tests have proved that as far as plastic sheets are concerned nothing but a modest reduction of the thickness In the separating lines is necessary for achieving an effect ensuring that the packing Is easily opened along said lines. The lat¬ ter applies in particular to the situation where the tearing up is effected parallel to the separating line, whereas a tearing up transverse to a welding seam/se¬ parating line is very difficult to carry out. According to a particular modification, the method uses a welding electrode, which is of a concave, especially substantially hollowed welding profile, as well as a depth stop. As a result, it is for instance in connec¬ tion with welding in a sheet of polyolefine of a thick- ness of 200 μm possible to produce a double seam in the material. The double seam includes two closely arranged, parallel separating lines interconnected at the ends, and an intermediary thickened strand or string of com¬ pressed sheet material. The string is easily pulled out of the sheet lengthwise so as thereby to separate the sheet. A welding of a gripping member, such as a wafer, onto the end of the string has furthermore the effect that it is particularly easy to grip the wafer on the completed packing so as to pull the string out of the sheet and thereby open said packing. Other modifications allowing production of an annular separating line in the sheet can be used for the production of a broad strip- shaped tearing-up strand or string. The latter strand or string can also be provided with a gripping member weld- ed thereon and in form of a wafer, which in turn is loosely secured to the sheet in such a manner that the sheet is not torn up unintendedly. It is obviuos that most of the drawbacks of the conven¬ tional heat contact welding are due to the effect of undesired amounts of heat in the areas inside and out¬ side the welding seams. A general reduction of the tem¬ perature, especially in the counter electrode, implies, however, a considerably lower production rate, and it must be assumed that the conventionally used counter electrodes involve problems of feeding the heat energy necessary for the welding sufficiently quickly to the welding spot unless the process is carried out at high temperatures. Especially in this respect the invention is particularly favourable because the used heat source allows a generation of the energy immediately at the welding spot as well as a control of the temperature in the counter electrode so efficiently that the optimum temperature always applies therein. So far tests indicate that it is possible to obtain sa- tisfactory results provided the temperature of the pulse heating wire(s) is controlled by means of the electronic regulator within a range of +. 4°C, especially within +. 2°C . The tests performed so far operate with a regulator of the type "Resistron type RES-220" by Ropex Industrie Elektronik GmbH, D 7120 Bietigheim-Bissinge , Germany. The quality of the welding carried out by the method according to the invention is not as sensitive to varia¬ tions in the thickness and the nature of the material as the quality of the conventional heat welding, but when several pulse heating wires are used it is according to the invention preferred to individually set and control the temperature and the heating period of the pulse heating wires. In addition the invention allows the use of intersecting pulse heating wires , which are mutually electrically Insulated and arranged on different levels, and furthermore a filling of at least a portion of the space found along a pulse heating wire on the level of an intersecting pulse heating wire opposite the inter¬ sections with a suitable heat—conductive material, such as a tape. According to a modification of the method according to the invention a pattern of pulse heating wires on the fixing plane is provided for each new welding pattern, the individual pulse heating wires being arranged so as to be movable in their longitudinal direction between electrically insulating, heat—conducting separating lay¬ ers arranged on the fixing plane. As a result, it is ensured that the individual pulse heating wires are kept stretched by means of suitable means in connection with the unavoidable extension during the heating procedure, whereby said pulse heating wires remain correctly po¬ sitioned. When a welding press with a welding plane and a fixing plane is used, it is according to the invention pre- ferred to arrange the pulse heating wire(s) by means of wire stretchers in slide mountings displaceable in slide guides at the edges of the fixing plane, and to arrange measuring sticks at the side edges of the fixing plane and the welding plane, said measuring sticks allowing a reading of the position of the welding electrode and an easy positioning of the pulse heating wire(s) in the correct position. In this manner the method allows pro¬ duction of a counter electrode in a very easy and fast manner. The welding press according to the invention is charac- terised in that the fixing plane is preferably a non- heated, especially water-cooled plane fixing a counter electrode comprising one or several pulse heating wires, which are mutually and outwardly electrically insulated and together cover the welding electrode, where each pulse heating wire communicates with a current source and an electronic regulator allowing an individual and very accurate setting and regulation of the temperature and the heating period for each pulse heating wire. The resulting welding press is considerably less expensive than a conventional welding press for heat contact weld¬ ing because the complicated heating and cooling device for the fixing plane has been avoided. In addition, no costs are involved for expensive counter electrodes be¬ cause, as mentioned, said counter electrodes are accord- ing to the invention made of tape or the like electric¬ ally insulating and heat-conducting materials in addi¬ tion to the pulse heating wires. Said pulse heating wires are relatively inexpensive compared to the conven¬ tional electrodes, and furthermore they can be reused in other electrode assemblies. Another advantage is found in the fact that the costs involved in the current sup¬ ply and the electronic regulator are relatively modest too. The welding press according to the invention is furthermore advantageous in the cold fixing plane pro— viding an excellent lay out place for the material to be welded without involving a risk of said material being damaged or the user being incommodated by heat. For many purposes of use, an advantage is according to the invention obtained by the welding and counter elec- trodes presenting an annular welding pattern. The advan¬ tage obtained is evident in connection with electrodes to be used for weld-cutting of articles from a sheet or a length of material, for welding on of annular ar¬ ticles, and for welding in of separating lines so as to produce tear—up strips or strings facilitating the open- ing of a packing. The welding press may advantageously be provided with a depth stop with a high setting accuracy, preferably a setting accuracy superior to +. 100 μm, especially su¬ perior to +. 20 μm, with the result that It Is always possible to produce a welding seam of an exact thickness responding to the material thickness involved and the purpose of the welding process. Thus it Is possible to perform heat weldings of an outstanding quality even in materials which are difficult to weld, such as polypro- pylene, and In thin and thick materials as well. A tear—up string requiring a particularly small amount of material and space can be produced by the welding electrode being of a concave, especially substantially hollowed welding profile. In this connection it is often possible in many situations only to use a single, recti¬ linear pulse heating wire as counter electrode with the result that the tool has been simplified and is less expensive. The used pulse heating wire presents advantageously a linear temperature/resistance ratio and is of a cross section of approximately 4 mm times 0.1 mm corresponding for instance to a 3 mm broad welding electrode, said pulse heating wire further comprising an active zone extending maximum 5 mm beyond the corresponding end re- strictions of the welding electrode, whereby the pulse heating wire is coppered or shaped in another manner outside the active zone so as to possess a high electric conductivity. In this manner a reliable control of the temperature in the pulse heating wire is obtained by means of the regulator, and the limitation of the active zone so as substantially to correspond to the dimensions of the welding electrode ensures achievement of the ne¬ cessary heating exactly in the welding area, but not outside said area. Although various types of regulators undoubtedly can be used for the control of the welding process, it is, how¬ ever, according to the invention preferred that the used electronic regulator is such that during the welding, such as at intervals of 20 milliseconds, it can measure the voltage across and the current intensity in the pulse heating wire and thereby provide an indication of the temperature of the pulse heating wire, whereby the regulator can correct deviations from the set value and control the temperature of the pulse heating wire during operation within a temperature range of +, 2 β C . As a re¬ sult, the temperature in the pulse heating wire can be reliably kept within the narrow temperature range of 8 β C which is the only temperature range that can be used for welding polypropylene. A particularly simple and inexpensive counter electrode is obtained by the pulse heating wire(s) being kept to the fixing plane and electrically insulated both rela¬ tive thereto, mutually, and outwardly by means of tape. In order to facilitate the alteration of the structure of the counter electrode, the pulse heating wire(s) may be secured at the ends to slide mountings by means of wire stretchers, said slide mountings being displaceable in guides along the side edges of the fixing plane. In this manner it is possible constantly to keep the pulse heating wires stretched and to easily move them by a displacement along the guides . A fast and reliable providing of the counter electrode on the fixing plane can furthermore be ensured by both the welding plane and the fixing plane being provided with measuring sticks along their side edges, the gradu¬ ations of said measuring sticks on the two planes exact¬ ly opposing one another. Once the welding electrode has been arranged on the welding plane, it is possible imme— diately to read on the measuring sticks where to place the counter electrode on the fixing plane. In order to additionally facilitate the above providing of the counter electrode, the fixing plane may be such that while guided on guides or in guideways it is dis- placeable between a welding position inside the press and a mounting position outside the press. In this man¬ ner the user need not bend over the fixing plane in the press, but can perform the mounting conveniently outside said press whereafter he pushes the fixing plane into the welding position in the press. The counter electrode may furthermore advantageously comprise mutually intersecting pulse heating wires ar¬ ranged on different levels and being mutually electric¬ ally insulated in the intersections, preferably by means of polyimide sheet, where at least a portion of the space found along a pulse heating on the level of an intersecting pulse heating wire has been filled with a suitable, heat—conducting material, such as tape, of substantially the same thickness as the pulse heating wires. In this manner it is indeed obtained that a counter electrode with intersecting pulse heating wires is provided with an almost plane surface, and further¬ more that the individual pulse heating wires operate electrically independent of one another. The results obtained so far have proved that often the slightly dif¬ fering distances presented to the various pulse heating wires by the material to be welded are of no practical importance for the result. It is besides easy to compen¬ sate for the above differences by operating with indivi— dually setable temperatures and welding periods for the individual pulse heating wires in the same welding pat- tern. The latter possibility of individually regulating the heat capacity of the individual pulse heating wires is furthermore of great importance when the material to be welded presents substantially differing thicknesses outside the various pulse heating wires. The used pulse heating wires are in principle standard wires and are available in a number of varying quali¬ ties, cross sectional dimensions, and lengths, both of rectangular and circular, oval or a more composite cross section, and thus it is possible to structure the count¬ er electrode with a plane, a curved or a more composite surface shape. Rectangular pulse heating wires are usually available in dimensions of a width of a few mm and a thickness in the magnitude 100 to 300 μm, but other dimensions are also available. It is possible to directly place such a thin pulse heating wire in a curved position across a portion of its longitudinal direction with the result that it is possible to weld across a surface with projecting projections. In this connection it may, however, be necessary to replace the welding electrode with a suitable holder-on and option¬ ally only involve a one—sided heat supply from the pulse heating wire. It is also possible to supply heat by means of pulse heating wires from both sides of the plastic material to be welded. In some cases it is in addition possible to shape the pattern of the counter electrode by means of a single specially produced pulse heating wire formed in the pattern in question. The welding electrode may be a conventional HF—electrode of a good quality. It is, however, advantageous to oper¬ ate with a cutting edge being higher than usually on such electrodes, because a compressing of the sheets in the welding seam appears to be less necessary than in connection with an HF-welding. Brief Description of the Drawing The invention is explained in greater detail below by means of embodiments and with reference to the accompa¬ nying drawing, in which Fig. 1 is a side view of the fundamental structure of a conventional welding press for heat contact welding, Fig. 2 is a perspective view of a portion of a welding press for a ruler welding according to the invention, Fig. 3 Is a diagrammatic view of a welding press accord- Ing to the Invention with electrodes for the welding of a square welding pattern, shown from the side, towards the welding plane, and towards the fixing plane, respec¬ tively, Fig. 4 is a side view of a portion of a fixing plane with a slide guide and wire stretchers, Fig. 5 illustrates a corner portion of the portion of Fig. 4 with measuring sticks and perpendicular to the fixing plane, Fig. 6 illustrates a fixing plane with two pairs of in— tersecting pulse heating wires, measuring sticks, slide guides, and wire stretchers, shown perpendicular to the plane, Fig. 7 Illustrates a welding plane with measuring sticks and welding electrode and mating the fixing plane with the electrode pattern shown in Fig. 6, Fig. 8 illustrates a corner portion of a fixing plane with the fundamental structure of a counter electrode with an intersection between two pulse heating wires, Fig. 9a. is a side view in principle of a welding tool for welding a ring onto a sheet, Fig- 9 is a to P view of the ring welded on, Fig. 9c. is a top view of the annular counter electrode used for the welding on of the ring, Fig. 10a. illustrates the fundamental structure of an annular parting seam for the formation of a tear-up string shown with a wafer welded thereon, Fig. 10b_ is a sectional view on a larger scale taken along the line B-B of Fig. 10a., the associated welding electrode profile being inserted, Fig. 10c. corresponds to Fig. 10a., but where the parting seam is placed in a packing with sliced food, Fig. 11a. illustrates the fundamental structure of a sec- ond annular welding seam for the formation of a tear-up strip shown with a wafer welded thereon, Fig. lib. is a perspective view of the welding tool with a welding electrode for carrying out the parting seam of Fig. 11a, Fig. lie. is a sectional view taken along the line C-C of the welding tool of Fig. lib., Fig.12a. illustrates a blister pack for a toothbrush with an annular parting seam welded therein for the tear-up strip with the wafer, and Fig. 12b. corresponds to Fig. 12a., but shown during the tear-up movement of the tear—up strip. Best Mode for Carrying Out the Invention Fig. 1 is a side view of the fundamental structure of a conventional heat press for heat welding. The heat press comprises a top plane 1 and a bottom plane 2, respec¬ tively. In sequence, the top plane comprises an alumi— nium plate 3 with a not shown heating device and a not shown thermostate, a top tool 5, and a welding plane 7 with a top electrode 8 (here the welding electrode) . Correspondingly, the bottom plane 2 comprises in se¬ quence an aluminium plate 4 with a not shown heating device and a not shown thermostate, a bottom tool 6, and a mounting plate 8 for a bottom electrode 10 (here the counter electrode) . The profile 15 of the top electrode appears here with a cutting edge, whereas the profile 16 of the bottom electrode is plane, whereby the shown plastic sheets 11, 12 are simultaneously provided with a parting seam during the welding. A separating tape 14 is inserted between the plastic sheets 11, 12 and the bot¬ tom electrode 10, said separating tape being made of a material of a higher melting point than the plastic sheets 11, 12, such as of polyimide. Fig. 2 illustrates an example of the fundamental struc¬ ture of the top plane and the bottom plane of a welding press according to the invention for ruler welding. The welding press comprises a top plane 1 fundamentally structured like the top plane 1 of Fig. 1, and a bottom plane In form of a relatively narrow fixing plane 20 optionally being water-cooled. A pulse heating wire 22 is mounted on the top side of the fixing plane 20 be¬ tween two strips of Teflon or Kapton—tape 24, 26 adhered to the fixing plane 20 and to one another, respectively, said adhering, however, being such that the pulse heat¬ ing wire 22 can be moved freely in its longitudinal di¬ rection between said strips 24, 26. The width of the pulse heating wire 22 is slightly larger than the width of the welding profile 15 on the welding electrode 9. The thickness of the pulse heating wire Is for instance 0.1 mm. At both ends, the pulse heating wire 22 Is stretched in a wire stretcher 23 secured to the fixing plane 20 and simultaneously operating as a current con¬ nector. Conduits 25 connect the pulse heating wire 22 with a current source 28 and an electronic regulator 27 capable of regulating the temperature in the pulse heat¬ ing wire within a range of + 2 β C relative to a set tem¬ perature . Fig. 3 is a diagrammatic view of the fundamental struc¬ ture of a welding press according to the invention for welding two-dimensional welding patterns, shown by way of a side view and sectional views along the line A-A and B-B, respectively. The illustrated welding press comprises four columns 31 mounted on the bottom plane 2 and operating as guides for the top plane 1. A welding electrode 9 with a square welding pattern is mounted on the top plane 1. The bottom plane 2 is here provided with a displaceable fixing plane 32 displaceable outside the top plane 1 with the result that the counter elec¬ trode 10 can be mounted on said fixing plane 32 while it is displaced outside the press. The illustrated counter electrode 10 comprises here four pulse heating wires 22 intersecting one another in pairs in the corners of the welding pattern. The pulse heating wires 22 may be ad¬ hered directly onto the fixing plane 32 with tape strips therebetween in such a manner that said pulse heating wires 22 can be moved in their longitudinal direction on the fixing plane and with a particular structure out of level in the intersections. The detailed structure of a wire intersection appears from Fig. 8. Depth stops pos- sessing a high adjustment accuracy can be adjustably secured to the bushings 18, 19 for the columns 31 for the setting of the minimum distance between the elec¬ trodes 9 and 10. Fig. 4 is a side view of a detail of a fixing plane 32 with a pulse heating wire 22 and an alternative mounting device for said wire. The pulse heating wire 22 is here secured at each end to a resilient wire stretcher 23 with a current connector 29. The wire stretcher ensures that the wire 22 is stretched at various temperatures and heat expansions. In turn, the wire stretcher 23 with the current connector 29 is secured to a slide mounting 30, which can be displaceably retained in a slide guide 35 by means of a screw 33 and a nut 34, said slide guide 35 in turn being secured to the edge of the fixing plane 32. The top side of the slide guide 35 is furthermore provided with a measuring stick 36 assisting in deter¬ mining the position of the pulse heating wire 22 on the fixing plane 32. Fig. 5 illustrates the fixing plane 32 described in con¬ nection with Fig. 4. Fig. 5 is a top view of the fixing plane comprising a pulse heating wire 22 mounted on a wire stretcher 23 and with a slide mounting 30 and a slide guide 35 as well as a measuring stick 36. In addi¬ tion, Fig. 5 shows a slide guide 35 and a measuring stick along the ad acent side of the fixing plane 32. Correspondingly, Fig. 6 is a top view of a fixing plane 32 with four pulse heating wires 22 stretched in a pat¬ tern of a counter electrode 10, where each pulse heating wire is provided with wire stretchers with current con¬ nectors and is mounted with slide mountings in the slide guide 35 and provided with a measuring stick 36. Fig. 7 is a bottom view of a top plane 1 with a welding electrode 9 mounted thereon in a pattern corresponding to the pattern of the counter electrode 10 of Fig. 6. Fig. 8 illustrates the structure of a counter electrode 10 on a fixing plane 32. The counter electrode 10 com¬ prises two intersecting pulse heating wires 22, 22' and has been supplemented with electrically insulating and heat—conducting Kapton—layers and strips of Teflon—tape. In sequence, the counter electrode 10 is structured as follows : a.. An electrically insulating and heat-conducting Kap- ton-layer 38 is placed on the fixing plane 32, atop which a strip of Teflon-tape 37 is adhered. b. The lower pulse heating wire 22 is mounted on top of the tape strip 37. c. A strip of Teflon-tape 40 is mounted across the low¬ er pulse heating wire 22 so as to abut the strip of Teflon-tape 37. d A transverse upper pulse heating wire 22' is mounted on top of the tape 40, followed by e. placing of an uppermost, electrically insulating and heat-conducting Kapton-layer 42 on top of the pulse heating wire 22' . Subsequently, the resulting counter electrode 10 com¬ prises two intersecting pulse heating wires 22, 22' , which are electrically insulated from the fixing plane, one another, and outwardly by means of the Kapton-layers and the Teflon-tape, and which in addition are of a uni- form thickness across the fixing plane 32 apart from in the intersection where an additional single layer of pulse heating wire is provided. The difference in thick¬ ness is usually of the magnitude 100 μm and is in prac¬ tice of no interfering importance. Figs. 9a., 9b., and 9c. show in principle an assembly with specially produced welding tools including annular elec¬ trodes 49, 22 for welding a circular plastic ring 51 onto a plastic sheet 52, while in the same process punching out a central portion of the sheet found at the centre of the ring. Fig. 9a. is a side, partially explod¬ ed view of the assembly, Fig. 9b. is a top view of the ring welded thereonto , and Fig. 9c. is a top view of the annular counter electrode. The tools include an upper welding plane 47 arranged on a top plane not shown, said welding plane being electrically heated. In addition, the tools include a welding electrode 49 with an annular welding pattern 57 and arranged on the welding plane, where the electrode presents an engraved welding profile 58. A punching needle 50 presenting a concave punching profile 59 is arranged at the centre of the electrode. The counter electrode comprises an annular pulse heating wire 22 with diametrically arranged inlets 22a,, 22b. for current connectors not shown and with a central opening 60 of a diameter being substantially larger than the diameter of the punching needle 50. The pulse heating wire 22 is secured with an intermediary electrically Insulating Teflon-layer 54 onto the top side of a steel roundel 55. The steel roundel 55 comprises a central opening 56, the edge of which assists the punching needle 50 in the punching. A second Teflon-layer 53 is arranged on top of the pulse heating wire 22, and the plastic sheet 52 and the ring 51 are arranged on top of the second Teflon—layer 53 in such a manner that the opening 61 in the ring, the opening 60 in the pulse heating wire, and the opening 56, respectively, in the roundel flush with the longitudinal axis of the punching needle 50. Fundamentally, the ring 51 is welded on in the same manner as described in connection with the ex¬ planation of the method according to the invention, viz. the welding electrode is pressed against the outer an— nular portion 62 of the ring 51, and the ring is welded by the pulse heat from the electrode 22 onto the sheet in said portion after the punching needle 50 having been inserted through the openings 61, 60, 56 in the ring, the pulse heating wire and the roundel having punched out an opening in the plastic material. The welding pro¬ vides the ring 51 with a profiled pattern 63 correspond¬ ing to the pattern 57 and the profile 58 in the annular welding electrode. As an alternative, the punching needle can be omitted and the ring and the electrodes can be provided with other shapes . Figs. 10a., 10b. ι and 10c. illustrate an example of the use of the invention for producing a tear-up string 76. Fig. 10a. and 10b. illustrate such a string 76 formed in and of a plastic sheet 71 during the welding of an annular parting seam with two closely arranged separating lines 72, 73. The separating lines are coherent at the ends 74, 75 and provided with a thickened central portion 76 made of compressed plastic material from the sheet 71, said central portion forming the string 76. Fig. 10b. is a sectional view along the line B-B of Fig. 10a. through the sheet 71 with the produced string 76 and a portion of the used welding electrode 77. It appears directly that the used electrode 77 presenting the concave pro¬ file with two pointed ends 72' , 73' and a concave hol¬ lowing 76' therebetween allows production of two paral¬ lel separating lines 72, 73 and a thickened portion 76 therebetween. Accurate depth stops in the press can en- sure that the sheet material 71 in the separating lines 72, 73 is not perforated, but remain air- and water¬ tight. Fig. 10a. illustrates furthermore a gripping mem¬ ber in form of a wafer 78 which is welded at 79 onto one end 75 of the string. Two opposing sides of the wafer 78 are welded at weldings 80 onto the sheet material 71 and are perforated at 81 inside said weldings 80. In this manner the wafer 78 is retained to the sheet 71 at con¬ ventional use, but when the perforations 81 are broken by the user inserting one finger at the arrow 82, said wafer is easily loosened. Subsequently by pulling in the wafer 78, the user can easily tear the string 76 out of the sheet 71 along the separating lines 72, 73. In Fig. 10c. the described tear-up string 76 has been used for a packing 83 for sliced food 84. Fig. 11a. illustrates the fundamental structure of a sec¬ ond annular parting seam 85 for the formation of a tear- up strip 86 In a plastic sheet 71, and Figs. lib. and lie. illustrate the associated welding electrode 87. The tear—up strip 86 is in turn formed by welding a circum¬ ferential parting seam 85 which then only includes a single separating line. A portion of a transverse plast¬ ic strip 88 is welded at one end of the strip 86 onto the tear—up strip 86 at 89 and along the sides to form a wafer 78. The wafer can be loosened by inserting a fin¬ ger at the arrow 90, whereafter the strip 86 can be torn up by a pull in the wafer 78. Fig. lib. illustrates the associated welding electrode 87 presenting a profile with only one cutting edge 91. The electrode 87 compris¬ es furthermore an extra profile portion 89' at one end to form the welding 89. Fig. lie. is a sectional view along the line C-C of Fig. lib. through the electrode 87, the shape of the cutting edge 91 and the extra profile portion 89' appearing. Figs. 12a. and 12b. illustrate the use of the invention for producing a tear—up strip 93 in a known blister pack 92 for a toothbrush. The production of the blister pack 92 starts with a forming of the container 94 in a manner known per se, whereafter the cover part 95 with a tear- up strip 93 of fundamentally the same type as the tear- up strip 96 of Fig. 11a. is welded onto the container 94 along the projecting circumferential flange 96 thereof. The tear—up strip 93 differs only from the strip 86 of Fig. 11a. by comprising a narrowing portion at 97. The illustrated tear—up strip is furthermore shaped as the strip 86 and operates in the same manner by means of a wafer 78 welded onto the strip 93 at 89 and along its sides, and which can be loosened by inserting a finger below the free end edge at the arrow 90 and subsequently used for pulling out the tear—up strip 93, as indicated by the arrows 98 and 99 in Fig. 12b..

Claims: Claims . 1. A method of welding an embossing and/or welding and/or parting seam in one or more layers of material containing heat-weldable, especially thermoplastic plastic material, by means of indirect heating of the plastics in a welding press, c h a r a c t e r i s e d by - using a combination of - a welding electrode arranged against one side of the material, said welding electrode in particular being an upper electrode of a welding profile and pattern mating the welding to be performed, - and a counter electrode of a corresponding pattern and arranged against the other side of the material and formed by one or several pulse heating wires, which are mutually and outwardly electrically in¬ sulated and cover the welding electrode and pre¬ ferably project a short distance beyond said welding electrode, where the pulse heating wire(s) is(are) secured to a preferably non-heated fixing plane, especially a water-cooled fixing plane, such as a bottom plane, and where each pulse heating wire com¬ municates with a current source and an electronic regulator, - as well as a heat-conducting separating tape ar¬ ranged between the pulse heating wire(s) and the material and being of a higher melting point than the plastic material, especially in form of a con¬ veyor belt for the material, - whereby the temperature of the welding electrode is kept constant and preferably below the softening point of the plastic material, - and where a current is shortly transmitted through the pulse heating wire(s) during the welding imme¬ diately before or after the welding press has been completely closed with the result that said wire(s) are heated and emit heat to the material, the elec¬ tronic regulator being set such that a very accu¬ rately controlled temperature is kept in the pulse heating wire(s) in a temperature range immediately above the melting point of the plastic material in question, and for a predetermined period being suf¬ ficiently long for ensuring the desired result, — whereafter the current through the pulse heating wire(s) is interrupted, the press is opened, and the material is immediately cooled on the cold fixing plane before fresh material is advanced for welding. 2. A method as claimed in claim 1, c h a r a c t e r ¬ i s e d by using welding and counter electrodes pre¬ senting an annular welding pattern. 3. A method as claimed in claim 1 or 2 , c h a r a c - t e r i s e d by using a welding press comprising a depth stop with a high setting accuracy for ensuring a minimum distance between the welding electrode and the counter electrode with the associated insulating layers during the welding procedure, and by setting the depth stop to a minimum distance corresponding to or being smaller than the total thickness of the material between the electrodes . 4. A method as claimed in claim 3, c h a r a c t e r ¬ i s e d by setting the depth stop to a minimum distance between the electrodes corresponding to an interval of approximately 20% and approximately 80%, especially be¬ tween approximately 30% and approximately 70%, of the thickness of the material between the electrodes . 5. A method as claimed in one or more of the preceding claims 1 to 4, c h a r a c t e r i s e d by using a welding electrode of a concave, especially substantially hollowed welding profile. 6. A method as claimed in one or more of the preceding claims 1 to 5, c h a r a c t e r i s e d by control¬ ling the temperature in the pulse heating wire(s) within a range of +. 4 β C, especially within +. 2"C by means of the electronic regulator. 7. A method as claimed in one or more of the preceding claims 1 to 6 , and where at least two pulse heating wires are used, c h a r a c t e r i s e d by indivi¬ dually setting and controlling the temperature and the heating period for the pulse heating wires . 8. A method as claimed in one or more of the preceding claims l to 7, c h a r a c t e r i s e d by using mu¬ tually intersecting pulse heating wires, which are mutu¬ ally electrically insulated and arranged on different levels, and by filling at least a portion of the space found along a pulse heating wire on the level of an in¬ tersecting pulse heating wire opposite the intersections with a suitable heat-conductive material, such as a tape . 9. A method as claimed in one or more of the preceding claims 1 to 8 , c h a r a c t e r i s e d by providing a pattern of pulse heating wires on the fixing plane for each new welding pattern, the individual pulse heating wires being arranged so as to oe movable in their longi¬ tudinal direction between electrically insulating, heat- conducting separating layers arranged on the fixing plane . 10. A method as claimed in one or more of the preceding claims 1 to 9 , and where a welding press with a welding plane and a fixing plane is used, c h a r a c t e r ¬ i s e d by arranging the pulse heating wire(s) by means of wire stretchers in slide mountings displaceable in slide guides at the edges of the fixing plane, and by arranging measuring sticks at the side edges of the fix¬ ing plane and the welding plane, said measuring sticks allowing a reading of the position of the welding elec¬ trode and an easy positioning of the pulse heating wire(s) in the correct position. 11. A welding press for carrying out the method as claimed in claim 1 and comprising a welding plane and a fixing plane, where the welding plane Is provided with a welding electrode of a welding profile and pattern mat¬ ing the welding to be carried out and the temperature of which can be kept constant within a temperature range of approximately 20"C to approximately 250 β C, and where at least one plane can be moved towards and away from the other plane, c h a r a c t e r i s e d in that the fixing plane Is preferably a non—heated, especially wat— er—cooled plane fixing a counter electrode comprising one or several pulse heating wires , which are mutually and outwardly electrically insulated and together cover the welding electrode, where each pulse heating wire communicates with a current source and an electronic regulator allowing an individual and very accurate set¬ ting and regulation of the temperature and the heating period for each pulse heating wire. 12. A welding press as claimed in claim 11, c h a r ¬ a c t e r i s e d by the welding and counter electrodes presenting an annular welding pattern. 13. A welding press as claimed in claim 11 or 12, c h a r a c t e r i s e d in that It is provided with a depth stop with a high setting accuracy, preferably a setting accuracy superior to +. 100 μm, especially su- perior to +. 20 μm. 14. A welding press as claimed in claim 11, 12 or 13, c h a r a c t e r i s e d by the welding electrode be¬ ing of a concave, especially substantially hollowed welding profile. 15. A welding press as claimed in one or more of the preceding claims 11 to 14, c h a r a c t e r i s e d by the used pulse heating wire presenting a linear tem¬ perature/resistance ratio and being of a cross section of approximately 4 mm times 0.1 mm corresponding for instance to a 3 mm broad welding electrode, said pulse heating wire further comprising an active zone extending maximum 5 mm beyond the corresponding end restrictions of the welding electrode, whereby the pulse heating wire is coppered or shaped in another manner outside the ac- tive zone so as to possess a high electric conductivity. 16. A welding press as claimed in one or more of the preceding claims 11 to 15, c h a r a c t e r i s e d by the used electronic regulator being such that during the welding, such as at intervals of 20 milliseconds, it can measure the voltage across and the current intensity in the pulse heating wire and thereby provide an indica¬ tion of the temperature of the pulse heating wire, whereby the regulator can correct deviations from the set value and control the temperature of the pulse heat- ing wire during operation within a temperature range of + 2 β C. 17. A welding press as claimed in one or more of the preceding claims 11 to 16, c h a r a c t e r i s e d in that the pulse heating wire(s) is(are) kept to the fixing plane and electrically insulated both relative thereto, mutually, and outwardly by means of tape. 18. A welding press as claimed in one or more of the preceding claims 11 to 17, c h a r a c t e r i s e d in that the pulse heating wire(s) is(are) secured at the ends to slide mountings by means of wire stretchers, said slide mountings being displaceable in guides along the side edges of the fixing plane. 19. A welding press as claimed in one or more of the preceding claims 11 to 18, c h a r a c t e r i s e d in that both the welding plane and the fixing plane are provided with measuring sticks along their side edges, the graduations of said measuring sticks on the two planes exactly opposing one another. 20. A welding press as claimed in one or more of the preceding claims 11 to 19, c h a r a c t e r i s e d in that while guided on guides or in guldeways the fix¬ ing plane is displaceable between a welding position inside the press and a mounting position outside the press. 21. A welding press as claimed in one or more of the preceding claims 11 to 20, c h a r a c t e r i s e d In that the counter electrode comprises mutually inter¬ secting pulse heating wires arranged on different levels and being mutually electrically insulated in the inter¬ sections, preferably by means of polyimide sheet, where at least a portion of the space found along a pulse heating on the level of an intersecting pulse heating wire has been filled with a suitable, heat—conducting material, such as tape, of substantially the same thick¬ ness as the pulse heating wires.

Inventors: NYBORG HENRIK, NYBORG, HENRIK
Applicants: WELDAN A S EVALD A NYBORG A S, WELDAN A/S (EVALD A. NYBORG A/S)
Application year: 1992
Main classification: B29C65
IPC codes: B29C65