Abstract:
A flexible ferromagnetic strip is used to induction-weld seams in polymer pipes. The strip is a blend of strontium ferrite, a surfactant, and an LDPE binder. A process to produce the profile is to mix the ingredients together followed by granulation and extrusion or calendering. The strip is used in conjunction with an induction coil sized to fit over a polymer pipe coupling containing the strip and separate segments of polymer pipe. The strip is heated by induction current induced by an electromagnetic field generated by the coil. The heated strip causes the polymer pipe segments to be thermoplastically welded together.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS AND CLAIM OF PRIORITY 
     This application claims priority under 35 U.S.C. 119(e) of U.S. Provisional Application Ser. No. 61/857,169 filed Jul. 22, 2013, the contents of which are incorporated herein by reference in its entirety. 
    
    
     BACKGROUND 
     This invention relates to providing a system for improved thermoplastic induction-welding. More particularly, this invention relates to new compositions of matter that can be used to induction-weld seams in polymer pipes. 
     Since the earliest days of plumbing, water and drainage pipes have been made of metal and connected by welding or threading. Threaded pipes are difficult to assemble and manufacture, and welding requires substantial skill and risks causing fire or other property damage due to extreme heat and hazardous fumes. More recently, plastic pipes such as PVC (polyvinyl chloride), ABS (acrylonitrile butadience styrene), and PE (polyethylene) pipes have been implemented; however, these require volatile, messy, and toxic solvents in order to bond properly. Improvements in bonding methodology would be helpful to improve bond quality and to reduce installation hazards. 
     SUMMARY OF THE INVENTION 
     The present invention provides a system overcoming the above-mentioned problems, which can be used to induction-weld seams in polymer pipes. The invention further provides such a system that is efficient, inexpensive, and handy to use. 
     In accordance with one aspect, this invention provides a system for thermoplastic induction welding of polymer pipes, including a flexible ferromagnetic strip configured to fit within a coupling of a polymer pipe; an electromagnetic induction coil configured to surround said coupling; and a power supply electrically connectable to said electromagnetic induction coil and configured to cause said coil to generate an electromagnetic field upon energizing thereof by said power supply; whereby a flow of current is induced in said ferromagnetic strip to heat said strip, resulting in thermoplastic welding of separate polymer pipe segments located within the coupling. 
     In accordance with another aspect, this invention provides a flexible ferromagnetic strip configured to fit within a coupling of a polymer pipe to cause thermoplastic induction welding of separate polymer pipe segments within the coupling upon heating of the strip by electromagnetic induction current, the ferromagnetic strip containing a polymer binder combined with at least one surfactant and at least one ferromagnetic material. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a perspective view illustrating a flexible ferromagnetic strip, configured to assist inductive thermal welding of thermoplastic pipe fittings, according to a preferred embodiment of the present invention. 
         FIG. 2  shows an exploded perspective view, illustrating the flexible ferromagnetic strip adjacent a female end fitting of a thermoplastic pipe, according to the preferred embodiment of  FIG. 1 . 
         FIG. 3  shows an exploded perspective view, illustrating a pair of flexible ferromagnetic strips positioned within a double female pipe coupler, according to the preferred embodiment of  FIG. 1 . 
         FIG. 4  shows a side view, illustrating the female end fitting of  FIG. 2  inductively welded to a thermoplastic pipe segment using the flexible ferromagnetic strip of  FIG. 1 . 
         FIG. 5  shows a side view, illustrating the double female pipe coupler of  FIG. 3  inductively welded to a pair of thermoplastic pipe segments using the pair of flexible ferromagnetic strips of  FIG. 3 . 
         FIG. 6  shows a diagrammatic perspective view, illustrating an inductive coil used to induce inductive heating in the flexible ferromagnetic strip of  FIG. 1 . 
         FIG. 7  shows a diagrammatic depiction, illustrating the formation of the flexible ferromagnetic strip using at least one extrusion process, according to a preferred method of the present invention. 
         FIG. 8  shows a diagrammatic depiction, illustrating the formation of the flexible ferromagnetic strip using at least one calender, according to a preferred method of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  shows a perspective view illustrating a preferred flexible ferromagnetic strip  102 , preferably configured to assist the thermal welding of thermoplastic pipe fittings using an inductive process, according to an aspect of the present invention.  FIG. 2  shows an exploded perspective view, illustrating the flexible ferromagnetic strip  102  adjacent a female coupling  104  of a thermoplastic pipe  106 , according to the embodiment of  FIG. 1 . Flexible ferromagnetic strip  102  is preferably configured to fit within the circular bore of a thermoplastic pipe fitting, as shown in  FIG. 2 . Preferably, the coupler strip is firmly adhered to the interior of a plastic pipe such as a HDPE (high density polyethylene) pipe. 
       FIG. 3  shows an exploded perspective view, illustrating a pair of flexible ferromagnetic strips  102  engaged within a double female pipe coupler  108 , according to the preferred embodiment of  FIG. 1 . Those skilled in the art will appreciate that, under appropriate circumstances, other coupling arrangements such as, for example, locating the ferromagnetic strip(s) at the outer face of the pipe, etc., may suffice. 
       FIG. 4  shows a side view, illustrating the female end fitting  104  of  FIG. 2  inductively welded to thermoplastic pipe segment  106  using the flexible ferromagnetic strip  102  of  FIG. 1 .  FIG. 5  shows a side view, illustrating the double female pipe coupler  108  of  FIG. 3  inductively welded to a pair of thermoplastic pipe segments  106  using the pair of flexible ferromagnetic strips  102  of  FIG. 3 . 
     In a preferred embodiment of the present invention, a flexible ferromagnetic strip  102 , consisting substantially of ferromagnetic particles embedded in a low-density polyethylene (LDPE) material, is preferably formed into a ring shape, as shown in  FIG. 1 . The ring is preferably embedded, or inserted, into the inner bore of a female coupling  104  of a thermoplastic pipe  106 . A length of thermoplastic pipe  106  is then inserted into the joint and held into position, primarily by friction. An electromagnetic induction coil  120  (see  FIG. 6 ) is preferably placed around the exterior of the joint, and an electromagnetic field is generated by the coil  120  by applying electric current at a predetermined frequency from a power supply  150 . This field produces inductive heating in the ferromagnetic strip  102 , which heating melts the surrounding thermoplastic pipe  106  segments, causing the segments to then fuse into a homogenous single length of pipe. This is similar to the effect of a chemical adhesion; however, it avoids the use of hazardous chemicals and tends to be stronger. 
     A preferred composition of ferromagnetic strip material is a low-density polyethylene (LDPE) binder combined with at least one surfactant and at least one ferromagnetic material. More specifically, the preferred material composition is a blend of strontium ferrite, a surfactant and an LDPE binder. Tables 1-5 below present preferred example compositions according to exemplary embodiments of the invention. A preferred ferromagnetic material is a sheet-grade strontium ferrite (sold under the tradename HM410 “Starbond” strontium ferrite powder by Hoosier Magnetics, Inc.) comprising “large” particle size. 
     
       
         
               
             
               
               
               
               
               
             
               
               
               
               
               
             
           
               
                 TABLE 1 
               
             
             
               
                   
               
               
                 Example 1 
               
               
                 Formula MF(S)1114 (50 Vol % Ferrite Powder) 
               
             
          
           
               
                   
                 Material 
                 Grade 
                 Weight (lbs) 
                 Weight % 
               
               
                   
               
             
          
           
               
                   
                 LDPE 
                 Marlex ® 1122B 
                 39.70 
                 15.55 
               
               
                   
                 BioRez 
                 66-116-A 
                 0.65 
                 0.25 
               
               
                   
                 Strontium 
                 410 Ferrite 
                 215 
                 84.20 
               
               
                   
                 Ferrite 
                 Powder 
                   
                   
               
               
                   
                 Total 
                   
                 255.35 
                 100.00 
               
               
                   
               
             
          
         
       
     
     
       
         
               
             
               
               
               
               
               
             
               
               
               
               
               
             
           
               
                 TABLE 2 
               
             
             
               
                   
               
               
                 Example 2 
               
               
                 Formula MF(S)1113 (35 Vol % Ferrite Powder) 
               
             
          
           
               
                   
                 Material 
                 Grade 
                 Weight (lbs) 1   
                 Weight % 
               
               
                   
               
             
          
           
               
                   
                 LDPE 
                 Marlex ® 1122B 
                 51.65 
                 25.55 
               
               
                   
                 BioRez 
                 66-116-A 
                 0.50 
                 0.25 
               
               
                   
                 Strontium 
                 410 Ferrite 
                 150 
                 74.20 
               
               
                   
                 Ferrite 
                 Powder 
                   
                   
               
               
                   
                 Total 
                   
                 202.15 
                 100.00 
               
               
                   
               
             
          
         
       
     
     
       
         
               
             
               
               
               
               
               
             
               
               
               
               
               
             
           
               
                 TABLE 3 
               
             
             
               
                   
               
               
                 Example 3 
               
               
                 Formula MF(S)1106 (35 Vol % Ferrite Powder) 
               
             
          
           
               
                   
                 Material 
                 Grade 
                 Weight (lbs) 1   
                 Weight % 
               
               
                   
               
             
          
           
               
                   
                 HDPE 
                 Hypel ® 
                 4.00 
                 26.25 
               
               
                   
                 BioRez 
                 66-116-A 
                 0.038 
                 0.25 
               
               
                   
                 Strontium 
                 410 Ferrite 
                 11.20 
                 73.50 
               
               
                   
                 Ferrite 
                 Powder 
                   
                   
               
               
                   
                 Total 
                   
                 15.238 
                 100.00 
               
               
                   
               
             
          
         
       
     
     
       
         
               
             
               
               
               
               
               
             
               
               
               
               
               
             
           
               
                 TABLE 4 
               
             
             
               
                   
               
               
                 Example 4 
               
               
                 Formula MF(S)1107 (35 Vol % Ferrite Powder) 
               
             
          
           
               
                   
                 Material 
                 Grade 
                 Weight (lbs) 1   
                 Weight % 
               
               
                   
               
             
          
           
               
                   
                 HDPE 
                 Hypel ® 
                 3.96 
                 25.99 
               
               
                   
                 BioRez 
                 66-116-A 
                 0.076 
                 0.50 
               
               
                   
                 Strontium 
                 410 Ferrite 
                 11.20 
                 73.51 
               
               
                   
                 Ferrite 
                 Powder 
                   
                   
               
               
                   
                 Total 
                   
                 15.236 
                 100.00 
               
               
                   
               
             
          
         
       
     
     
       
         
               
             
               
               
               
               
               
             
               
               
               
               
               
             
           
               
                 TABLE 5 
               
             
             
               
                   
               
               
                 Example 5 
               
               
                 Formula MF(S)1112 (35 Vol % Ferrite Powder) 
               
             
          
           
               
                   
                 Material 
                 Grade 
                 Weight (lbs) 1   
                 Weight % 
               
               
                   
               
             
          
           
               
                   
                 HDPE 
                 Novapol ® 
                 4.00 
                 26.25 
               
               
                   
                 BioRez 
                 66-116-A 
                 0.038 
                 0.25 
               
               
                   
                 Strontium 
                 410 Ferrite 
                 11.20 
                 73.50 
               
               
                   
                 Ferrite 
                 Powder 
                   
                   
               
               
                   
                 Total 
                   
                 15.238 
                 100.00 
               
               
                   
               
             
          
         
       
     
     Upon reading this specification, those with ordinary skill in the art will now appreciate that, under appropriate circumstances, considering such issues as user preferences, cost, structural requirements, available materials, technological advances, etc., other material compositions such as, for example, MDPE binders, HDPE binders, etc., may suffice. 
     Through extensive experimental testing, applicant determined that a strontium ferrite loading of greater than or equal to about 50 vol % is most preferred. Applicant determined that a strontium ferrite loading of less than about 30 vol % fails to produce an adequate thermal weld and is therefore less preferred. The composition is also less preferred if the coupler strip is too brittle (that is, the sheet must wrap around a cylinder having an outer diameter of about 4½ inches). General mechanical properties of the preferred compositions are provided in Tables 6-8 below. 
     
       
         
               
               
               
               
             
           
               
                 TABLE 7 
               
               
                   
               
               
                   
                   
                 35 Vol % Ferrite 
                 50 Vol % Ferrite 
               
               
                   
               
             
             
               
                   
                 Date 
                 May 24, 2013 
                 May 24, 2013 
               
               
                   
                 Date Made 
                 May 24, 2013 
                 May 24, 2013 
               
               
                   
                 Formula 
                 MFS1113 
                 MFS1114 
               
               
                   
                 Shore D 
                   
                   
               
               
                   
                 Br 
                   
                   
               
               
                   
                 Hc 
                   
                   
               
               
                   
                 Hcl 
                   
                   
               
               
                   
                 Bh max 
                   
                   
               
               
                   
                 Millage (″) 
                 .0864-.0991 
                 .0812-.1040 
               
               
                   
                 Density 
                   
                   
               
               
                   
                   
                 Same Day 
                 Same Day 
               
               
                   
                 Tensile Strength 
                 937 
                 1080 
               
               
                   
                 Elong @ Break 
                 6.4 
                 2.5 
               
               
                   
                 Yield Strength 
                 1007 
                 1120 
               
               
                   
                 Elong @ Yield 
                 5.3 
                 2.5 
               
               
                   
                 Stiffness 
                 190 
                 448 
               
               
                   
                   
                 24 hr dwell 
                 24 hr dwell 
               
               
                   
                 Tensile Strength 
                   
                   
               
               
                   
                 Elong @ Break 
                   
                   
               
               
                   
                 Yield Strength 
                   
                   
               
               
                   
                 Elong @ Yield 
                   
                   
               
               
                   
                 Stiffness 
                 #DIV/0! 
                 #DIV/0! 
               
               
                   
                 Bend Test 4.5″ Pipe 
                 Pass 
                 Pass 
               
               
                   
                 Binder Polymer 
                 LDPE (Marlex) 
                 LDPE (Marlex) 
               
               
                   
                 Surfactant 
                 BioRez (.25%) 
                 BioRez (.25%) 
               
               
                   
                 Mixer - Extruder 
               
               
                   
               
             
          
         
       
     
     
       
         
               
             
               
               
               
             
           
               
                 TABLE 6 
               
               
                   
               
               
                 50 Vol % Ferrite 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Date 
                   
               
               
                   
                 Date Made 
                   
               
               
                   
                 Formula 
                 MFS1114 
               
               
                   
                 Thickness (″) 
                 0.0617 
               
               
                   
                 Shore D 
                 63 
               
               
                   
                 Br 
                 1309 
               
               
                   
                 Hc 
                 1350 
               
               
                   
                 Hcl 
                 2155 
               
               
                   
                 Bh max 
                 0.36 
               
               
                   
                 Density 
                 2.98 
               
               
                   
                   
                 Same Day 
               
               
                   
                 Tensile Strength 
                 1325 
               
               
                   
                 Elong @ Break 
                 5.0 
               
               
                   
                 Yield Strength 
                 1478 
               
               
                   
                 Elong @ Yield 
                 4.7 
               
               
                   
                 Stiffness 
                 314 
               
               
                   
                   
                 24 hr dwell 
               
               
                   
                 Tensile Strength 
                 1394 
               
               
                   
                 Elong @ Break 
                 4.7 
               
               
                   
                 Yield Strength 
                 1533 
               
               
                   
                 Elong @ Yield 
                 4.2 
               
               
                   
                 Stiffness 
                 365 
               
               
                   
                 Bend Test 4.5″ Pipe 
                 Pass 
               
               
                   
                 Binder Polymer 
                 LDPE (Marlex) 
               
               
                   
                 Mixer - Extruder 
               
               
                   
               
             
          
         
       
     
     
       
         
               
               
               
               
             
           
               
                 TABLE 8 
               
               
                   
               
               
                   
                 35 Vol % 
                 35 Vol % 
                 35 Vol % 
               
               
                   
                 Ferrite 
                 Ferrite 
                 Ferrite 
               
               
                   
               
             
             
               
                 Date 
                   
                   
                   
               
               
                 Hcl 
                   
                   
                   
               
               
                 Bh max 
                   
                   
                   
               
               
                 Millage (″) 
                 .050-.052 
                 .0490-.0510 
                 .037-0.483 
               
               
                 Density 
                 2.34 
                 2.34 
                 2.32 
               
               
                   
                 Same Day 
                 Same Day 
                 Same Day 
               
               
                 Elong @ Yield 
                   
                   
                   
               
               
                 Stiffness 
                 #DIV/0! 
                 #DIV/0! 
                 #DIV/0! 
               
               
                   
                 24 hr dwell 
                 24 hr dwell 
                 24 hr dwell 
               
               
                   
                 at 140 F. 
                 at 140 F. 
                 at 140 F. 
               
               
                 Elong @ Yield 
                   
                   
                   
               
               
                 Stiffness 
                 #DIV/0! 
                 #DIV/0! 
                 #DIV/0! 
               
               
                 Bend Test 4.5″ Pipe 
                 Pass 
                 Pass 
                 Pass 
               
               
                 Binder Polymer 
                 HDPE (Hypel) 
                 HDPE (Hypel) 
                 HDPE (Novapol) 
               
               
                 Surfactant 
                 BioRez (.25%) 
                 BioRez (.50%) 
                 BioRez (.25%) 
               
               
                 Lab Mixer - Lab 
                   
                   
                   
               
               
                 Mill 
               
               
                   
               
             
          
         
       
     
     Flexible ferromagnetic strip  102  is preferably formed using one of several preferred processes.  FIG. 7  shows a diagrammatic depiction, illustrating at least one extruder  130  used to extrusion-form the flexible ferromagnetic strip  102 , according to one preferred method of the present invention.  FIG. 8  shows a diagrammatic depiction illustrating at least one calender or series of hard pressure rollers  140  used to calender-form the flexible ferromagnetic strip  102 , according to another preferred method of the present invention. Preferred processes to produce the profile is to mix the ingredients together followed by granulation and extrusion (see  FIG. 7 ) or calendering (see  FIG. 8 ). Alternate preferred production processes utilize combinations of extrusion and calendering, as shown. Upon reading this specification, those skilled in the art will appreciate that, under appropriate circumstances, considering such issues as design preference, user preferences, marketing preferences, cost, structural requirements, available materials, technological advances, etc., other production arrangements such as, for example, molding, milling, co-molding, co-extrusion, etc., may suffice. 
     Applicant determined that better loading ferromagnetic material was achieved when LDPE is used. Furthermore, applicant determined that the resulting product was less brittle. The filler dispersing agent (surfactant) allows higher loadings of the strontium ferrite in polyethylene while maintaining good flexibility. The surfactant increases the toughness, tear strength, and elongation of the coupler strip/sheet. A preferred surfactant is an organic surfactant, preferably comprising a polyester resin such as BioRez® 66-116-A, commercially available from Advanced Images Resources, Alpharetta, Ga. Alternately preferably, the surfactant preferably comprises stearic acid. Alternately preferably, the surfactant comprises calcium stearate. Alternately preferably, the surfactant comprises at least one tackifying resin such as at least one abietic acid ester, at least one rosin ester, or at least one terpene phenolic resin. Such at least one rosin ester preferably comprises rosin esters sold under the trademark Foral® or Pentrex™. Alternately preferably, the surfactant comprises at least one styrene-acrylate copolymer such as Pliolite® AC-L. Alternately preferably, the surfactant comprises at least one acrylate copolymer resin such as Pliolite® LV72. Alternately preferably, the polymer binder comprises other thermoplastics or thermoplastic combinations. 
       FIG. 6  shows a diagrammatic perspective view, illustrating an inductive coil  120  used to induce inductive heating in the flexible ferromagnetic strip  102  of  FIG. 1 . The blend of strontium ferrite, LDPE, and BioRez® melts by induction heating at the correct temperature to fuse with HDPE pipe. For induction heating to be effective, the volume of strontium ferrite in the formulation needs to be at least 30% by volume. Applicant&#39;s preferred induction heating formulation contains from 30-75% by volume of ferrite powder. An optimum formulation of 50 vol % strontium ferrite was formulated with good flexibility 
     In testing, successful joining of pipe members was achieved using an induction frequency of about 400 Hz, which was observed to produce melt temperatures within the region of the ferromagnetic material of about 300-degree Fahrenheit (F). In an alternate preferred embodiment of the present system, the ferromagnetic material is preferably set into an additional wire mesh located inside the coupler to control field, flow, and physical position of the thermoplastic forming the pipe fitting. 
     Although applicant has described applicant&#39;s preferred embodiments of this invention, it will be understood that the broadest scope of this invention includes modifications such as diverse shapes, sizes, and materials. Such scope is limited only by the below claims as read in connection with the above specification. Further, many other advantages of applicant&#39;s invention will be apparent to those skilled in the art from the above descriptions and the below claims.