Source: http://www.google.com/patents/US4414166?dq=6985872
Timestamp: 2014-03-07 09:29:12
Document Index: 275416075

Matched Legal Cases: ['art 10', 'art 20', 'art 10', 'art 10', 'art 20', 'arts 10', 'art 10', 'art 10', 'art 20', 'art 10', 'arts 10', 'arts 10']

Patent US4414166 - Laser joining of thermoplastic and thermosetting materials - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsThermoplastic materials are joined to non-thermoplastic materials such as thermosetting materials by laser radiant energy which causes the thermoplastic material to flow onto the thermosetting material, preferably into a notch or groove or over a shoulder or lip to form a joint by mechanically locking...http://www.google.com/patents/US4414166?utm_source=gb-gplus-sharePatent US4414166 - Laser joining of thermoplastic and thermosetting materialsAdvanced Patent SearchPublication numberUS4414166 APublication typeGrantApplication numberUS 06/336,650Publication dateNov 8, 1983Filing dateJan 4, 1982Priority dateJan 4, 1982Fee statusLapsedAlso published asDE3269896D1, EP0084631A1, EP0084631B1Publication number06336650, 336650, US 4414166 A, US 4414166A, US-A-4414166, US4414166 A, US4414166AInventorsPaul M. Charlson, Clarence R. Schwieters, Jun H. SoukOriginal AssigneeInternational Business Machines CorporationExport CitationBiBTeX, EndNote, RefManPatent Citations (12), Referenced by (36), Classifications (34), Legal Events (4) External Links: USPTO, USPTO Assignment, EspacenetLaser joining of thermoplastic and thermosetting materialsUS 4414166 AAbstract Thermoplastic materials are joined to non-thermoplastic materials such as thermosetting materials by laser radiant energy which causes the thermoplastic material to flow onto the thermosetting material, preferably into a notch or groove or over a shoulder or lip to form a joint by mechanically locking the materials together.
We claim: 1. A method for joining thermoplastic material to thermosetting material comprising the steps of:forming a projection locking surface on the thermosetting material, causing the termoplastic material to melt and flow merely by projecting a laser beam to impinge upon the thermoplastic material at the area adjacent to said locking surface, the melted material flowing out of its own plane over said locking surface to form a joint at the interface between the thermosetting and thermoplastic materials. 2. The method of claim 1 where the beam is projected for about 0.5 seconds to 5 seconds.
TECHNICAL FIELD This invention relates to a method for joining a thermoplastic piece of material to a non-thermoplastic piece of material.
BACKGROUND ART The joining of thermoplastic materials with thermosetting materials by fusion welding is not feasible because the two materials do not unite by flowing. The thermoplastic material will flow, but the thermosetting material will not flow. Hence, the two materials will not unite by welding. On the other hand it is well known to join two pieces of thermoplastic materials together by laser welding as in U.S. Pat. No. 3,989,778 for Method of Heat Sealing Thermoplastic Sheets Together Using A Split Laser Beam by R. F. Osborne.
DISCLOSURE OF THE INVENTION Thermoplastic material is joined to thermosetting material by applying radiant energy to the thermoplastic material to cause it to flow over the thermosetting material to form a mechanical joint at an interface between the two materials.
BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic view illustrating the parts to be joined by the present invention where the parts are located within an enclosure having access holes;
EXAMPLE 1 The thermosetting part 10 of FIG. 1 is made of phenolic material which is a thermosetting material. Part 20 to which part 10 is to be joined is a 30% medium filled glass polycarbonate material. Phenolic was used for part 10 because of its electrical properties. The 30% medium filled glass polycarbonate material was chosen for part 20 because of its ease of moldability and stability after molding. Parts 10 and 20 were joined to each other at three different areas using 1.06.mu. radiation of a low power YAG laser with a beam impingement time of approximately 5 seconds. This produced a joining of the two parts at the three areas with a pull strength of approximately 18 pounds. The laser beam did cause some polycarbonate charring at the point where the core of the beam struck the polycarbonate but a uniform melt area was created to form a joint. A uniform melt area can be widened by defocusing the laser beam. This also minimizes the localized burning of the polycarbonate.
The beam angle of incidence was only approximately 10 horizontal axis. A greater angle of incidence such as a 45 would be preferable but in situations such as in FIG. 1 where the parts are in an enclosure the angle of incidence was restricted. It would be possible but perhaps not practical to insert mirrors into the enclosure 30 so as to increase the angle of incidence.
EMAMPLE 2 In this example the phenolic part 10, FIG. 3, had substantially the same shape and dimensions as the part 10 of FIG. 2. The polycarbonate part 20, however, did not have a rim or shoulder 21 confronting the lip or shoulder 11 of part 10 and thus there is no gap or channel 15 as in FIG. 2. The laser used in this example was a CO.sub.2 laser having 10.6 μm radiation with a cylindrical lens 0.04 by 0.40 inches focal size which extended the joining area along the interface between parts 10 and 20. The parts were joined using 40 watts with exposure times of 0.5, 1.0, and 2.0 seconds. The beam was directed at three areas producing three joints to join the parts 10 and 20 with an average pull strength of 4.2 pounds, 6.2 pounds, and 10.0 pounds corresponding to exposure times of 0.5, 1.0 and 2.0 seconds respectively. It was noted that the radiation energy from the high power CO.sub.2 laser could increase the temperature of the polycarbonate so rapidly that the melt did not have enough time to reflow. Although process time can be reduced by using the CO.sub.2 laser, joint strength is less than that when using the YAG laser with a longer exposure time.
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