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WO2002038356A1 - Procede de fabrication et dispositif utilisant des ultrasons de grande puissance - Google Patents

Procede de fabrication et dispositif utilisant des ultrasons de grande puissance Download PDF

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Publication number
WO2002038356A1
WO2002038356A1 PCT/US2000/030964 US0030964W WO0238356A1 WO 2002038356 A1 WO2002038356 A1 WO 2002038356A1 US 0030964 W US0030964 W US 0030964W WO 0238356 A1 WO0238356 A1 WO 0238356A1
Authority
WO
WIPO (PCT)
Prior art keywords
tool
flowable material
aperture
bore
mold
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2000/030964
Other languages
English (en)
Inventor
Ronald R. Manna
Alvin W. Russell
Dan Voic
Theodore A. D. Novak
David Ng
Salvatore Pantano
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Misonix LLC
Original Assignee
Misonix LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Misonix LLC filed Critical Misonix LLC
Priority to PCT/US2000/030964 priority Critical patent/WO2002038356A1/fr
Publication of WO2002038356A1 publication Critical patent/WO2002038356A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/0261—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould using ultrasonic or sonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • B29C43/40—Moulds for making articles of definite length, i.e. discrete articles with means for cutting the article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/46—Means for plasticising or homogenising the moulding material or forcing it into the mould
    • B29C45/56—Means for plasticising or homogenising the moulding material or forcing it into the mould using mould parts movable during or after injection, e.g. injection-compression moulding
    • B29C45/568—Applying vibrations to the mould parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B29C65/081—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations having a component of vibration not perpendicular to the welding surface
    • B29C65/082—Angular, i.e. torsional ultrasonic welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B29C65/083—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil
    • B29C65/085—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil using a rotary sonotrode
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B29C65/083—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil
    • B29C65/087—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil using both a rotary sonotrode and a rotary anvil
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B29C65/088—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using several cooperating sonotrodes, i.e. interacting with each other, e.g. for realising the same joint
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/74—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area
    • B29C65/743—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc
    • B29C65/7435—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc the tool being a roller
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/74—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area
    • B29C65/743—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc
    • B29C65/7443—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc by means of ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/431—Joining the articles to themselves
    • B29C66/4312—Joining the articles to themselves for making flat seams in tubular or hollow articles, e.g. transversal seams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81411—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat
    • B29C66/81421—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave
    • B29C66/81423—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave being concave
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81431—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single cavity, e.g. a groove
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
    • B29C66/8351—Jaws mounted on rollers, cylinders, drums, bands, belts or chains; Flying jaws
    • B29C66/83511—Jaws mounted on rollers, cylinders, drums, bands, belts or chains; Flying jaws jaws mounted on rollers, cylinders or drums
    • B29C66/83513—Jaws mounted on rollers, cylinders, drums, bands, belts or chains; Flying jaws jaws mounted on rollers, cylinders or drums cooperating jaws mounted on rollers, cylinders or drums and moving in a closed path
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • B29C43/361—Moulds for making articles of definite length, i.e. discrete articles with pressing members independently movable of the parts for opening or closing the mould, e.g. movable pistons
    • B29C2043/3636—Moulds for making articles of definite length, i.e. discrete articles with pressing members independently movable of the parts for opening or closing the mould, e.g. movable pistons ultrasonically or sonically vibrating, e.g. sonotrodes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/95—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94
    • B29C66/951—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 by measuring or controlling the vibration frequency and/or the vibration amplitude of vibrating joining tools, e.g. of ultrasonic welding tools
    • B29C66/9513—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 by measuring or controlling the vibration frequency and/or the vibration amplitude of vibrating joining tools, e.g. of ultrasonic welding tools characterised by specific vibration frequency values or ranges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2023/00—Tubular articles
    • B29L2023/001—Tubular films, sleeves
    • B29L2023/002—Sausage casings

Definitions

  • This invention relates to a manufacturing process.
  • the invention also relates to an associated apparatus.
  • the process and apparatus may be used exemplarily in the manufacture of elongate, axially symmetric products.
  • the product After extruding and shaping, the product will be cooked fuliy so that the customer needs only to heat it thoroughly for final preparation.
  • the present invention is directed to the use of mechanical pressure waves or vibrations, particularly including, but not necessarily limited to, pressure waves or vibrations of one or more ultrasonic frequencies, in a manufacturing process wherein at least an outer layer of a flowable or fluidic material is hardened by the vibrations applied to the flowable material.
  • the mechanical pressure waves may be applied to the flowable material in a batch type process using mold cavities or in a continuous type process using surfaces defining a flow aperture or passageway. Where the process is of the continuous type, elongate products having an axis of symmetry may be made. Other shapes may alternatively be manufactured as discussed herein.
  • the invention is derived in part from the observation that high power ultrasonic waves have various effects on mammalian tissue, whether living or dead. Depending upon the frequency and amplitude of vibration and the configuration of the ultrasonic tool, effects such as cutting, cavitation ablation and blood vessel coagulation have been noted.
  • a method pursuant to the present invention may operate on a flowable material such as hardened resin chips suspended in a polymeric matrix, or such as wood or ceramic particles in an adhesive or binder matrix, etc., to manufacture a product such as a structural member or a dowel.
  • a flowable material such as hardened resin chips suspended in a polymeric matrix, or such as wood or ceramic particles in an adhesive or binder matrix, etc.
  • products manufacturable pursuant to the present invention include plantable rods or capsules wherein fertilizing chemicals, and optionally seeds and pesticides, are embedded in a matrix of a hydrophilic composition.
  • Semi-solid or flowable mixtures contemplated as within the scope of possible feedstuffs or feed stocks for processing by the present invention include, but are not limited to, the feed stocks of industrial processes whose output, such as for example animal feed or fertilizer capsules, is not intended for human consumption. These feed stocks may all be characterized as capable of undergoing useful and irreversible physical and chemical changes upon the injection of energy.
  • cooking In addition to changes in the chemistry of the raw ingredients, cooking is often accompanied by a permanent change in physical state, typically in the direction of transformation of liquid or semi-solid or, generally, flowable pre-cooked states, into non-flowable or solid post-cooked states, as is well known in the case of doughs, batters, etc.
  • a flowable material in is placed contact with a surface, and the surface is then vibrated to transfer energy to the flowable material.
  • the surface is vibrated at one or more ultrasonic frequencies and transfers sufficient energy to the flowable material to at least partially harden or cure at least an outer layer of the mass of flowable material.
  • the present invention relates to the processing of any flowable material (usually a mixture of components) which may undergo useful chemical and physical changes upon energy injection, where the mixture produces an edible or inedible end product. The chemical and physical changes result in at least a partial hardening of the flowable material.
  • Ultrasonic tools have been well described in texts and invention disclosures for the last 50 years. Basically, a resonant body is activated with a transducer of either the magnetostrictive type or piezoelectric type.
  • the piezoelectric transducer can be a single crystal or, more commonly, a Langevin sandwich type where multiple crystals are held together between a front and rear mass with compression bolts.
  • the tools of the prior art may be of a simple cylindrical rod type or a complex machining with shapes cut into the surface to accept workpieces of various configurations such as automotive tail lamp lenses. These tools have been used for ultrasonic cleaning, cell disruption and welding of thermoplastics or some metals.
  • ultrasonic vibration can occur in four modes.
  • One is longitudinally, where expansion and contraction takes place essentially along the major axis of the wave carrying body.
  • a second mode called "transverse"
  • a distal tip of the wave-carrying body whips from side to side.
  • a third mode is radial vibration, where the part is expanding and contracting along a radial dimension.
  • Torsional vibration is also possible, where the part is twisting. All of these modes are useful in creating a skinning effect pursuant to the present invention, although some modes are preferred over others.
  • One tool configuration pursuant to the present invention that has proven effective for generating a skin on an elongate flowable composition is a radial ring resonator where multiple transducers are placed in vibration transmitting contact against the circumference of the tool. If the frequency of vibration of the transducers is the same as a radial resonant mode of the tool, then the tool be driven into sympathetic resonant vibration. The result will be that the inner diameter (ID) of the tool will expand and contract radially.
  • ID inner diameter
  • a flowable mixture may be pumped through the annulus of the tool, generating a skin along an outer surface of the mixture as the mixture passes the vibrating surface of the annulus.
  • Simple cutters may be used to produce cylindrical shapes of any desired length. Additional tools may be used to provide a rounded end shape to the cylindrical extrudate. Although a circular cross sectional shape is standard in many industries, it is envisioned that any geometric cross section may be made available by configuring the annular space, so that it assumes for example a cross-section in the shape of a star, a hexagon, a triangle, etc.
  • a ring resonator as used in the present invention may be characterized by its geometry wherein a height or longitudinal dimension of the ring, as measured parallel to the axis thereof, is equal to or less than that of the outer diameter of the ring. If the longitudinal dimension is significantly greater than that of the diameter, a tubular resonator is formed.
  • a second arrangement of apparatus for generating a skin on a mixture of particulate components employs, in accordance with the present invention, tools designed to operate in a longitudinal mode, that is with waves compressively transmitted along an axis of wave propagation.
  • a cylindrical bore is provided in a tool so that the bore has an axis essentially perpendicular to the wave propagation or longitudinal axis of the tool.
  • an angle of rotation about a the major axis of a cylindrical bore may be described as "azimuth,” then the non-uniformity of processing associated with the above described variation in amplitude of motion at the surface of the bore may be compactly described as showing unacceptable variation in azimuthal angle.
  • the second part is statically rotated through an angle of between approximately 10° and 170° around the common bore axis of the aligned parts, that is, in azimuth, more uniform processing may be obtained.
  • multiple stages may be envisioned whereby several tools are placed in series to produce more uniform product or longer processing times. In this arrangement, the tools do not have to be driven synchronously, although this could be done on an optional basis if preferred.
  • a third arrangement of an apparatus for generating a skin on a flowable material or mixture is a modification of the second.
  • a tool otherwise identical to one described in the preceding paragraph is truncated by a plane perpendicular to the longitudinal or wave propagation axis thereof and containing the major axis of the bore, thereby bisecting the bore.
  • the truncated tool thereby includes a semi- cylindrical depression. It is found in this case that the tool may be designed so that the "wings" formed at the sides of the semi-cylindrical cut out, that is the edges or lips of the resulting depression, vibrate transversely.
  • the wings will move laterally in and out of the resulting semi-bore with a greater amplitude than that realized in the corresponding bore region of non-truncated part.
  • the forgoing composite tool station may be described as a single annular or tubular resonator which has been bisected by a number of half- planes originating at the principal axis of the bore, the number of half planes in the first instance being two. Therefore, a further modification of this adaptation is to multiply the number of segments of a single annular tool station beyond two, each segment being driven by a separate transducer. Each segment end or head must be sealed to adjacent ones so that mixture cannot leak out from the resulting bore. In this modification, multiple stages deployed along a common bore or extrusion axis are not generally needed, since each annular segment is designed and constructed to achieve equal vibratory output. A more uniform processing results.
  • a mold may be constructed for batch or unit processing in distinction to the continuous processing contemplated in the previously described embodiments.
  • a clam shell type mold is constructed in the same fashion as those found on injection mold machines. Both the top and bottom tools or mold halves are ultrasonically vibrated. By placing the tool halves together, injecting the mixture through a suitable port and activating the tools ultrasonically, a molded cylindrical shape may be formed. Then, by opening the mold and tipping the bottom mold, the formed product may be expelled from the device.
  • Closing the mold and injecting mixture starts another cycle.
  • Another embodiment places a ball of mixture in the cavity and close the mold around it, thereby pressing a desired shape.
  • the secondary design question whether the tool shall be monolithic or segmented (which must at least be answered by provision of two segments in the case of a mold to allow ejection of the processed product), may also be answered in the case of a mold with multiplication of tool segments beyond two, thereby forming a mold cavity with a multiplicity of acoustically independently drivable surfaces, and allowing the tool designer more detailed control of surface deflection amplitudes.
  • Another method of achieving greater control of surface deformations of a single tool block is to multiply the transducers or points of excitation on a single tool part without segmentation.
  • a ring resonator for generating a skin on an extruded mixture may have provision, in accordance with the present invention, for mounting multiple transducers on the periphery of the element, as is discussed in greater detail below.
  • the ring resonator is designed using techniques known to the art so that a radial resonance mode is at or very near the desired operating frequency. Frequency of operation of resonators in accordance with the present invention has been varied from low ultrasonic frequencies ( ⁇ 20,000 Hz) to very high frequencies ( ⁇ 60,000 Hz) with reasonable results.
  • the frequency of operation will entail a decrease in the outer diameter of the resonator ring elements, given a fixed inner diameter dictated by the desired size of the finished product.
  • the ring dimension parallel to product movement, or thickness, is somewhat arbitrary but will have an affect on the resonant frequency of the ring.
  • the transducer outputs must be synchronized by any one of many methods known to the art. Otherwise, one transducer may expand while another contracts, setting off vibrations of opposite sign which could lead to wave cancellation and a non vibrating device.
  • a typical mounting arrangement for a ring resonator assembly in accordance with the present invention places a sealing ring on each side of an annular aperture to prevent the extruded mixture from oozing out under pressure.
  • Screw type pumps, pneumatic pumps or piston pumps well known to the art may be used to force the mixture through the annular aperture.
  • a transport system for moving the flowable particulate composition advantageously provides a certain amount of increased mixture static pressure to ensure that the skin to forms properly on the flowable particulate composition.
  • a back pressure is set up in the system which serves to keep the slurry in contact with the ID of the ring so that proper skin formation takes place.
  • Other means of inducing back pressure may be constructed by those schooled in the art within the contemplation of the present invention.
  • Yet another embodiment of the present invention when using a ring, tubular, or longitudinal resonator with a through bore, is to taper the bore from proximal to distal end slightly.
  • the converging section causes a back pressure to build during conveyance of a flowable mixture or slurry, thereby keeping the mixture in contact with the inner surfaces of the resonator.
  • Ring resonators allow only a small linear distance of surface contact between the ultrasonically vibrated ring and the extruded product. As the flow rate of the mixture increases, the contact time, which is the critical variable in some cases, decreases. To gain process time, additional rings may be stacked in series, as has been disclosed above. Another method of gaining process time with increasing flow rate is to fashion a tubular resonator. Although similar in concept, the tubular resonator is more difficult to analyze and may have nodes (points of no motion) and antinodes (points of maximum motion) at many points along the surface.
  • an alternate method of achieving a longer processing path relative to that of a ring or annular resonator is by drilling a bore through a single tool block designed to support standing ultrasonic compressional waves perpendicular to a wave transmission axis, that is, in a longitudinal mode.
  • This tool block may have a rectangular, square or round cross section as known in the art.
  • a cross bore is drilled in the tool in a direction essentially perpendicular to the longitudinal axis of the tool itself. The diameter of the bore should be approximately ! that of the width of the tool at that point.
  • the bore should be located as close as practical to the vibrating end or antinode of the tool. This positioning of the bore will tend to maximize vibrations developed at the surfaces of the bore.
  • the other end or input antinode of the tool is attached to a vibration generating transducer by means of a threaded stud or bore.
  • the mating faces of the tool and the transducer are tightened together by means of a wrench. By mating the faces together, the transducer and tool become a single tuned member that has a common resonant frequency and can be driven by ultrasonic frequency generators known to the art.
  • a second identical tool/transducer arrangement may be positioned next to the first and aligned so that the bores communicate.
  • a ring seal advantageously polytetrafluoroethylene, may be fashioned so that the feedstock slurry does not leak from the interface and so that the vibrating metal parts do not touch.
  • the second tool is advantageously statically rotated between 10° and 170° with respect to the first tool about a common bore axis.
  • a modification of the bored tool concept entails, in accordance with the present invention, truncating the tool in a plane perpendicular to the longitudinal axis thereof and bisecting the bore.
  • This advantageously places the centerline of the bore at an antinode of the tool, where maximum displacement occurs, and further, the sides, or wings, of the truncated tool are found to deform inwards and outwards with greater amplitude than the corresponding region of the untruncated tool, giving a more even skinning effect.
  • the resulting probe is easier to analyze by conventional techniques as well.
  • a second tool must be mounted exactly opposed to the first so that the faces adjoin. A thin sealing pad is inserted between them to prevent leakage and prevent direct contact between tool bodies.
  • two or more sets of tools may be arranged in series to improve symmetry of skin formation.
  • molds may be employed to form skin-bearing product on a piecewise basis rather than extruding a continuous solid cylindrical product or linked train of segments.
  • a feedstock mixture is pumped through a tool or composite tool on a continuous basis. This allows maximum efficiency or throughput.
  • only the outer circumferential surface of the cylindrical extrudate is sealed by the ultrasound.
  • the shape of the ends tends to be flat or square cut, unless the processing line is provided with peripheral equipment to form the end shapes.
  • a mold may be formed from two ultrasonic tools. Both tools have a cavity which is a half section of the finished product shape, and are driven by separate transducers. Synchronization of the drives is not necessary.
  • a clam shell type mold is constructed similarly to commercial injection mold machines.
  • a typical manufacturing process for a sealed molded product in accordance with the present invention comprises 1) spraying a food grade grease onto two mold halves, 2) bringing the two halves of the mold together by means of hydraulic, pneumatic or linear motors, 3) injecting a curable feedstock mixture into a cavity in the adjacent mold halves by means of ports in either or both mold halves, 4) ultrasonically vibrating the mold halves for a predetermined time period, after which the ultrasonic vibration is stopped, and 5) separating the mold halves and ejecting a formed product by a conventional piston or by tilting the bottom mold half. If the mold halves are oriented vertically instead of horizontally, the formed product could drop free from mold under gravity force alone. It is to be noted that a thin pad of polytetrafluoroethylene or other suitably inert material must be disposed between the mold halves for sealing and tool isolation. A sealing strip or O-ring may be substituted.
  • the construction material for the resonator element or elements is chosen to have good acoustic properties such as high Q and low internal loss.
  • the material should be fairly resistant to erosion caused by cavitation or the sliding friction of viscous material flow. Where foodstuffs come into direct contact with the resonator, that element must be approved for by the FDA for commercial use.
  • Stainless steel is normally specified for food handling equipment since that material is sufficiently hard and non-reactive to resist corrosion and other erosive effects when the machinery is repeatedly sterilized by steam. However, the internal losses of stainless steel are fairly high when that material is used in an acoustic resonator. Titanium has been proven to be an acceptable material in all respects; however, in some cases stainless steel or even aircraft grade aluminum may be substituted.
  • FIGS. 1A, 1 B, 1C and 1 D are perspective diagrams illustrating the various known modes of vibration of an ultrasonic tool.
  • FIG. 2A is a perspective view of a ring resonator or annular ultrasonic tool, illustrating the placement of ultrasonic transducers, in accordance with the present invention.
  • FIG. 2B is a perspective diagram depicting the ring resonator of Fig 2A, with the addition of inlet and outlet tube for feedstock mixture flow.
  • FIG. 3A is a perspective view of a block ultrasonic tool with a bore drilled perpendicular to a longitudinal axis of vibration.
  • FIGS. 3B and 3C are schematic elevational views each schematically depicting a major mode of vibration of the tool illustrated in Fig. 3A.
  • FIG. 4A is a schematic perspective view of an ultrasonic tool with a bore, sectioned perpendiculary to a longitudinal vibration axis of the tool, in accordance with the present invention.
  • FIG. 4B is a perspective of a pair of ultrasonic tools sectioned as shown in Fig. 4A, placed adjacently so as to form a new bore, in accordance with the present invention.
  • FIG. 5 is a perspective diagram of a further variation of the embodiment of Fig. 4B, showing multiple tool segments placed circumferentially adjacent to each other to form a single bore, in accordance with the present invention.
  • FIG. 6 is an exploded perspective diagram of a pair of clam shell style mold halves in accordance with the present invention, each mold half constituting an ultrasonic tool.
  • FIGS. 7A, 7B, 7C are schematic elevational views of ring resonators or annular tools, illustrating the placement of ultrasonic transducers thereon, in accordance with the present invention.
  • FIG. 8A is a schematic perspective diagram of a processing train in accordance with the present invention.
  • Fig. 8B is a perspective view, on a larger scale, of an illustrative section of product shown in Fig. 8A.
  • FIG. 9 is a schematic perspective view of a further embodiment in accordance with the present invention, illustrating a tubular resonator for forming a skin or shell on an extruded product.
  • FIG. 10 is an exploded schematic perspective view of a further embodiment of the present invention, illustrating a pair of block resonators in accordance with Fig. 3, disposed at spaced angular positions about a bore axis.
  • FIGS. 11A, 11 B are a schematic front and a side elevation depicting a die block tool in accordance with the present invention, for the formation of rounded end segments.
  • FIG. 12 is a schematic elevational view of a mechanism, in accordance with the present invention, incorporating a die block and a ring resonator tool for the formation of a complete traditional sausage-type shape.
  • FIG. 13 is a perspective diagram of a further specialized tool shape in accordance with the present invention, for forming rounded ends on a manufactured product.
  • FIG. 14 is an elevational view illustrating the mode of employment of a pair of tools as disclosed in Fig. 13.
  • FIG. 15 is a perspective view of the tools shown in Fig. 14.
  • FIG. 16 is an elevational view of a modification of a plurality of modified tools, further showing a mode of employment of those tools.
  • FIG. 17 is an elevational view of a modification the tools of Fig. 16.
  • DETAILED DESCRIPTION OF INVENTION Acoustically activated, and in particular ultrasonic, tools may be designed to resonate (vibrate) in four modes, as shown in Figs. 1A-D.
  • a first, longitudinal, mode of vibration illustrated in Fig. 1A
  • an elongate tool 30 is energized to expand and contract essentially along its major axis.
  • Tool 30 is provided with a threaded stud or post 31 for operatively connecting or coupling the tool to an electromechanical transducer assembly (not illustrated).
  • a second type of mode (Fig. 1 B) is called transverse, wherein a differently designed tool 32 whips from side to side at its free tip.
  • a tool 34 expands and contracts, as illustrated in Fig. 1C.
  • Torsional vibration as shown in Fig. 1 D, is also possible, where a tool 36 is constrained to twist.
  • Tools 32, 34 and 36 are respectively provided with threaded studs 33, 35 and 37 for operative attachment to transducer assemblies, as before.
  • Tools may alternatively be provided with a female threaded coupling, that is, a threaded bore, for mechanical coupling with a threaded stud on an electromechanical transducer assembly (not illustrated). All of these modes are useful in generating a skin on a flowable particulate mass, although some modes are preferred over others in this application.
  • Electromechanical transducer assemblies 40 may comprise a stack of disk shaped electromechanical transducer elements 401 on a central post (not visible), partially contained by a sleeve 402 and resting at a lower or distal end on a flange 403.
  • An extension 404 of the central post is provided with opposing lands 405 operatively engageable by a torquing tool or wrench for connecting assembly 40 to a tool part such as disk shaped body 43 via a threaded post and bore (not visible), with sufficient rigidity so that transducer assembly 40 and tool body 43 act as a single acoustically vibrating body, as is known in the art.
  • Electromechanical transducer assemblies such as assembly 40 and the coupling of them to metal tool bodies being well known in the art and not an improvement of the present invention, electromechanical transducer assemblies will hereafter be referred to simply as "transducers", standard components as described above being understood.
  • the aperture 50 may be of any geometric cross-section, such as a star shape, hexagon, triangle, etc.
  • Simple cutting or termination devices may be used to produce axially symmetric or partially symmetric product shapes of any length (not shown). Alternately, the termination devices may be configured to provide rounded terminations, as illustrated in Figs. 11A, 11 B and 12.
  • a die block section 52 illustrated in Figs. 11A and 11 B surrounds a substantially quarter-spherical cutout defined by a recessed surface 54, adjoining a front face 58 and a bottom face 60.
  • the quarter spherical cut-out communicates with a substantially semi- cylindrical section defined by a further recessed surface 56, which extends to a rear face 62 of die block 52.
  • two die block sections 52 may be regarded as fused along rear face 62 to form a single die block 64, as illustrated in Fig. 12.
  • composite die block 64 may be manufactured as a single piece.
  • a pair of die blocks 64 are mounted adjacent to tool 38, as illustrated in Fig. 12, and operatively connected to rods or brackets 66, or other means for transmitting compressive forces.
  • a cylindrical product extrudate 68 passes between opposing die blocks 64, which are periodically pressed together by rods or brackets 66 in a motion parallel to arrow A to form constricted sections or linkages 70 between adjacent links or segments 69.
  • Transducers 40 (Figs. 2A and 2B) may be periodically cycled on and off in coordination with the reciprocation of die blocks 64 in order to permit the formation of linkages 70 in previously unprocessed sections of extrudate or segmented train 68.
  • a continuous skin formed by tool 38 on extrudate 68 may be simply broken and reformed by action of die blocks 64 if a less fine surface texture at linkages 70 is acceptable.
  • Die blocks 64 are, of course, operatively connected to electroacoustic transducers (not illustrated) to enable a skin forming operation, and provided with a low-friction sealing layer at face 60 to prevent direct contact of opposing tools and possible product leakage.
  • the extrudate is illustrated here as a continuous train of product segments, semi-cylindrical recessed surface 56 may be reduced or eliminated to form unconnected product segments which fall free after the end forming operation; in this case the processing station may be advantageously oriented so that arrow B points in a vertically downward direction, so that completed links 69 fall free under gravity.
  • a spool- shaped tool 72 (Fig. 13) is provided with a groove or circumferential recess defined by a curved semi-cylindrical surface 74, and circumferential lands 76.
  • the recess defined by surface 74 is periodically interrupted by end surfaces 78 contiguous with surface 74.
  • End surfaces 78 are essentially identical to the quarter-spherical working surfaces 54 and 56 of die block sections 52, modified along with contiguous surfaces 74 to conform to a circumference of spool 72.
  • a threaded central bore 79 is provided at a principal axis of spool 72, centered on lateral face 71 , as an attachment point for an ultrasonic transducer.
  • a pair of synchronously excitable transducers 150 and 151 are mounted at threaded bore 79 to opposite faces lateral 71 and 73 of spool 72, thereby simultaneously serving as axles or spindles for rotation (Fig. 14).
  • a pair of spools 72 are mounted adjacently and configured to synchronously counter-rotate, producing a bore 154 defined by moving semi- cylindrical surfaces 74.
  • Electrical operation of ultrasonic transducers 150, 151 attached to a rotating tool may be accomplished by provision of a co-rotating ultrasonic power supply powered by brush contacts (not separately illustrated). The above described mode of operation of end-formers 72 is further illustrated in Fig.
  • extrudate 154 output from an operation creating a cylindrical skin (not separately illustrated), passes between rotating and ultrasonically active spools 72, whereby a periodic juxtaposition of opposing end forming surfaces 78 shapes the ends of, creates new skin surface on, and severs individual product segments or links.
  • the links then fall free and may be handled in subsequent processing operations by standard methods known in the art.
  • Spools 72 are illustrated as producing approximately three links or segmented products per rotation.
  • An alternative embodiment shown in Fig. 16 utilizes smaller diameter spools 156 with end-forming surfaces 158 to produce one link per rotation.
  • the smaller size of tools or spool shapes 156 may permit use of a single transducer 160 mounted to each tool.
  • spool 156 may be replaced by two half-spools 162 and 164 formed by symmetrical bisection of spool 156 along a plane interface parallel to the lateral faces thereof, in analogy to the bisection of a tool illustrated in Figs. 4A and 4B, as shown in Fig. 17.
  • transducers 166 and 168 need not be operated synchronously, insofar as a layer of insulating material (not separately designated) is inserted at interface 170.
  • a pair of vertically mounted spools rotating about horizontal axes may be provided with vertical baffle plates co-planar with faces 71 and 73 (Figs. 13-15), thereby forming a hopper above a nip between the spools, the spools being configured to move surfaces 74 downward through the bore or processing region 152.
  • a curable flowable mixture filling the hopper is partially gravity fed and partially drawn between the rotating spools, to form completed product shapes in one operation.
  • FIG. 3A An alternative embodiment of the present invention is illustrated in Fig. 3A.
  • a tool 84 is designed to operate in a longitudinal mode, with waves compressively transmitted along an axis of wave propagation 92 coincident with an axis of bore 86, which is adapted to receive an ultrasonic transducer assembly.
  • a cylindrical bore 88 with an axis 90 essentially perpendicular to the wave propagation or longitudinal axis 92 of tool 84 is provided.
  • tool 84 does not by itself form a symmetrical skin on a cylindrical product.
  • Those portions of surfaces 88 which are essentially parallel to longitudinal axis 92 do not stiffen the surface of a curable product mixture as those effectively as surface portions which lie essentially perpendicular to the axis, a situation which may be by comparison of Fig. 3A to a representation in Fig. 1A of an exemplary longitudinal tool: Excluding the effect of the bore itself, surfaces perpendicular to the axis of wave propagation tend to oscillate in step with planar pressure waves, whilst surfaces perpendicular to these planes tend to remain stationary. This leads to non-uniform processing around the periphery of a cylindrical extruded product. However, where another tool of the same dimensions is placed next to the first tool 84 with a seal in between, so that the bores communicate, a more uniform processing may be obtained.
  • tool blocks 92 and 94 are separated by a seal ring 96, which may be manufactured of a chemically and physically stable deformable seal material, for example, polytetrafluoroethylene.
  • Ring 96 is fashioned so that the feedstock slurry does not leak from the interface between blocks 92 and 94 and so that vibrating metal parts do not touch.
  • Tool 94 is advantageously disposed at an angle of between 10° and 170° about a common bore axis 98 with respect to tool 92. This angular staggering of tools 92 and 94 will allow even skin formation. Multiple stages may be envisioned whereby more than two tools are placed in series to produce more uniform product and/or longer processing times (not illustrated).
  • FIG. 4A a tool 100 is truncated along a plane P1 extending axially through a bore 101 and perpendicular to a longitudinal axis 103 of wave transmission,.
  • Tool 100 is thus formed to have a shaft 93 and a head 95 provided with a semi- cylindrical recess (not separately designated) representing half of bore 101 , and further provided with a pair of elongate land surfaces 97 and 99 flanking the semi-cylindrical recess and extending in plane P1.
  • a new bore 101' is formed, as shown in Fig. 4B, so that two tools form a composite tool assembly Cp, replacing a single tool.
  • low-friction sealing gaskets are placed between the opposing land surfaces 97 and 99 of tools 100 and 102.
  • Azimuthal uniformity of processing may be still further improved, as discussed in the preceding paragraph with reference to monolithic tools 92 and 94, by disposing multiple composite tool stations Cp at different orientations around a common bore axis (not separately illustrated).
  • azimuthal uniformity of processing may be improved in accordance with the present invention by increasing tool block segmentation about a principal bore axis in a single stage, as illustrated in Fig. 5.
  • a multiplicity of tool segments 104 each is driven by a separate transducer (not shown).
  • tool segments 104 are longitudinal resonators with end shapes or heads 105 which are essentially respective sectors of an annulus.
  • Tool segments 104 and heads 105 are designed to allow three or more resonators to form a circular bore 107.
  • An elastomeric or fluorocarbon type sealing material (not separately shown) is bonded to heads at lateral faces 106 thereof to prevent product leakage and prevent tools 104 from touching.
  • each vibrating tool 104 is independent of the other resonators, so each resonator 104 may be driven to a different amplitude to achieve a perfect symmetrical skin or shell. Multiple stages are not contemplated as necessary, since each tool or resonator 104 may be designed and constructed to achieve vibratory output equal to the other tools or resonators. A more uniform processing of an outside surface of an extruded product will result.
  • a flowable particulate mixture is pumped through a tool or composite tool on a continuous basis. This process tends to maximize throughput. However, only the cylindrically circumferential surface of the extrudate is sealed by the ultrasonic wave energy. As the resulting cylinder is simply cut to length, the shape of the ends would tend to be flat or square cut, unless the processing line is provided with peripheral equipment, e.g. Fig. 12, to form rounded end shapes.
  • a mold may be formed from two ultrasonic tools 108 and 110, as illustrated in Fig. 6. Both tools 108 and 110 have a cavity 111 which is a half section of the finished product shape and are driven by separate electromechanical, e.g. piezoelectric, transducers (not illustrated). Synchronization of the drives is not necessary.
  • a clam-shell type mold 113 comprising mold-half tools 108 and 110 is similar in construction to molds used in injection mold machines. Both the top tool 108 and bottom tool 110 are ultrasonically vibrated.
  • a molded cylindrical shape 112 may be formed. Then, by opening mold 113 and tipping the bottom mold 110, molded shape 112 may be expelled from the device. Closing the mold and injecting another aliquot of particulate mixture starts another cycle.
  • a ball of mixture is pre- positioned in the half cavity (not illustrated) to be formed by juxtaposed cavity halves 111 , and the mold is closed around the ball, thereby pressing the ball into a desired shape.
  • Figs. 7A-C depict ring resonators 114, 116 and 118 with transducers 120, 122 and 124 in wave-transmitting engagement with lands on outer circumferential surfaces of the resonators.
  • These ring resonators 114, 116 and 118 are dimensioned so that the frequency of a radial resonance mode is at or very near the desired operating frequency.
  • the symmetry of oscillation at the ID of the ring is the product will not have a skin created evenly around a periphery, and may fall apart during subsequent processing.
  • FIG 8A A typical mounting or process train arrangement for this type of system is shown in Fig 8A.
  • a feedstock mixture is made and held in a whipper or homogenizer 132 and passes therefrom to a pump 130, which feeds the mixture under an effective overpressure through an inlet tube 134 to a processing region or aperture defined by an internal surface 136 in a ring resonator tool 138.
  • Screw-type pumps, pneumatic pumps or piston pumps well known to the art and generically illustrated by pump 130 may be used to force the feedstock mixture through the ring resonator tool 138 equipped with standard transducer assemblies 40. Processed mixture or extrudate leaves the ring resonator tool 138 and particularly the aperture thereof through an exit tube 140.
  • Sealing rings 128 on each side of tool 138 at the interface thereof with inlet and exit tubes 134 and 140 respectively prevent the feedstock mixture from oozing out under pressure, and prevent the direct contact of metal parts at least one of which is ultrasonically vibratable, which may otherwise become welded together during operation.
  • a length of finished product 142 is illustrated in Fig. 8B, with a more detailed cross section thereof illustrated by magnified inserted view 144.
  • Skin 146 is formed to a depth of deposition of sufficient energy by ultrasonic penetration, while interior region 148 remains unaltered, and ready for further cooking steps.
  • One of ordinary skill in the art will appreciate that the various tools, composite tools and processing trains may be modified to form further, equivalent tools, combinations of tools and processing trains. For instance, a composite annular tool with three resonator segments may be operatively combined and sealed to the end of, for example, a monolithic longitudinal resonator tool.
  • the present invention can find applications in other fields of industry, for example, in the processing of organic waste materials into fertilizers logs which may be planted along with seeds.
  • the disclosed process and apparatus may be used in the manufacture from flowable materials of such products as hardened resin chips suspended in a polymeric matrix, wood or ceramic particles in an adhesive or binder matrix, etc. Possible products include dowels and structural members.
  • Foodstuffs made in accordance with the present invention need not be intended for direct human consumption, but may be intended for the feed of domestic animals, e.g., cattle. Accordingly, it is to be understood that the drawings and descriptions herein are proffered by way of example to facilitate comprehension of the invention and should not be construed to limit the scope thereof.

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Abstract

L'invention concerne un mélange semi-solide de matière non comestible qui est porté au contact d'une surface vibrante d'un moule (113) doté de deux outils vibrants (108, 110) creusés d'une cavité (111), l'énergie étant transportée à travers la surface jusqu'au mélange pour former une forme cylindrique moulée (112). Le mélange est injecté dans le moule (113) de côté à travers un port défini par des surfaces (115), après couplage des deux outils vibrants (108, 110). La vibration est généralement d'une fréquence ultrasonore, et l'injection d'énergie est suffisante pour entraîner des modifications physiques et chimiques locales dans les mélanges sensibles à ces modifications et, globalement, pour entraîner des changements dans le sens d'une résistance à la traction et à l'écoulement accrues. Une peau se forme généralement sur le mélange, et avec une efficacité de traitement plus importante que si cette peau avait été formée par des moyens purement thermiques.
PCT/US2000/030964 2000-11-10 2000-11-10 Procede de fabrication et dispositif utilisant des ultrasons de grande puissance Ceased WO2002038356A1 (fr)

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PCT/US2000/030964 WO2002038356A1 (fr) 2000-11-10 2000-11-10 Procede de fabrication et dispositif utilisant des ultrasons de grande puissance

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EP2027778A1 (fr) * 2007-05-29 2009-02-25 Laboratories Development LLC Préparation de formes solides de produits pour les secteurs alimentaires, de la santé, pharmaceutiques, phitofarma, vétérinaires, les pesticides et les fertiliseurs en utilisant l'aide de vibrations à ultrasons
CN106312288A (zh) * 2016-09-29 2017-01-11 中国船舶重工集团公司第七〇九研究所 一种高精度多焊接头超声波焊接装置

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JPH1167802A (ja) * 1997-08-20 1999-03-09 Ricoh Co Ltd モールド装置
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US3483918A (en) * 1966-12-14 1969-12-16 Interlake Steel Corp Continuous casting
JPS61181630A (ja) * 1985-02-07 1986-08-14 Beishin Kogyo Kk 粉粒体の成形方法
US5122993A (en) * 1989-03-07 1992-06-16 Mitsubishi Mining & Cement Co., Ltd. Piezoelectric transducer
US5202066A (en) * 1989-04-25 1993-04-13 Idemitsu Kosan Co., Ltd. Method of plasticizing molding material and apparatus therefor
US5422049A (en) * 1993-11-08 1995-06-06 Friedrich Theysohn Gmbh Method and apparatus for the plastifying of synthetic resins
US5955035A (en) * 1994-03-16 1999-09-21 Skf Usa Inc. Method and apparatus for devulcanization of cross-linked elastomers
US5679248A (en) * 1995-12-19 1997-10-21 Kimberly-Clark Worldwide, Inc. Coextruded blocks and applications therefor
JPH1167802A (ja) * 1997-08-20 1999-03-09 Ricoh Co Ltd モールド装置

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2027778A1 (fr) * 2007-05-29 2009-02-25 Laboratories Development LLC Préparation de formes solides de produits pour les secteurs alimentaires, de la santé, pharmaceutiques, phitofarma, vétérinaires, les pesticides et les fertiliseurs en utilisant l'aide de vibrations à ultrasons
CN106312288A (zh) * 2016-09-29 2017-01-11 中国船舶重工集团公司第七〇九研究所 一种高精度多焊接头超声波焊接装置
CN106312288B (zh) * 2016-09-29 2019-12-13 中国船舶重工集团公司第七一九研究所 一种高精度多焊接头超声波焊接装置

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