Spin-welding of polymeric components having large surface area or non-complementary weld interfaces

Patent metadata

Field	Value
Publication number	US-2016176103-A1
Application number	US-201414574699-A
Country	US
Kind code	A1
Filing date	Dec 18, 2014
Priority date	Dec 18, 2014
Publication date	Jun 23, 2016
Grant date	—

Abstract

Friction-weld assemblies and methods of spin-welding are provided, where the components being joined are polymeric components. Designs provided for the polymeric components enable the use of relatively low speeds and pressures to achieve superior friction weld joints between the components. Further, large surface area polymeric components can be successfully friction welded with such designs. In certain variations, at least one polymeric component has a weld surface with a plurality of surface features that are concave (e.g., grooves) or convex. In other variations, the first component in the weld region has a distinct non-complementary shape from the second component, thus creating a progressive advancing weld line that avoids high temperatures that might incur damage to the polymeric component and weld joint. Such component designs additionally provide for improved flash management at the weld joint.

First claim

What is claimed is:

1 . A friction-weld assembly, comprising:
a first polymeric component comprising a first weld surface defining a first shape and comprising a plurality of surface features, wherein each respective surface feature is concave or convex; a second polymeric component comprising a second weld surface defining a second shape, wherein one of the first shape or the second shape is convex, while the other of the first shape or the second shape is concave; and a friction weld joint formed between the first weld surface and the second weld surface, wherein one of the first polymeric component or the second polymeric component remains stationary on a fixed tool, while the other of the first polymeric component or the second polymeric component is rotatable on a rotating tool during friction welding that forms the friction weld joint.

2 . The friction-weld assembly of claim 1 , wherein at least one of the first polymeric component or the second polymeric component is formed from a composite material comprising a thermoplastic polymer and a reinforcement material.

3 . The friction-weld assembly of claim 1 , wherein the plurality of surface features is a plurality of grooves, wherein each groove of the plurality of grooves has an orientation perpendicular to a direction of rotation and extends from a central region of the first weld surface to an outer perimeter of the first weld surface.

4 . The friction-weld assembly of claim 1 , wherein the plurality of surface features comprises a plurality of grooves comprising greater than or equal to about 3 to less than or equal to about 182 grooves on the first weld surface.

5 . The friction-weld assembly of claim 1 , wherein the plurality of surface features comprises a plurality of grooves comprising a first plurality of grooves defining a first length and a second plurality of grooves defining a second length less than the first length.

6 . The friction-weld assembly of claim 5 , wherein the plurality of grooves further comprises a third plurality of grooves defining a third length that is less than both the first length and the second length.

7 . The friction-weld assembly of claim 1 , wherein the plurality of surface features comprises a plurality of grooves, wherein each groove of the plurality of grooves has a width of greater than or equal to about 0.5 mm to less than or equal to about 3 mm and a depth of greater than or equal to about 0.5 mm to less than or equal to about 3 mm.

8 . The friction-weld assembly of claim 1 , wherein the plurality of surface features comprises a plurality of grooves, wherein each groove of the plurality of grooves defines a shape on the first weld surface selected from the group consisting of: a triangle, a rectangle, a quadrilateral, and combinations thereof.

9 . The friction-weld assembly of claim 1 , wherein the first shape and the second shape are complementary with respect to one another.

10 . The friction-weld assembly of claim 1 , wherein the first shape and the second shape are substantially round shapes.

11 . The friction-weld assembly of claim 1 , wherein at least one of the first weld surface or the second weld surface has a surface area corresponding to the friction weld joint of greater than or equal to about 3,000 mm 2 (about 4.7 in 2 ).

12 . The friction-weld assembly of claim 1 , wherein the plurality of surface features comprises convex surface features that serve as energy directors, wherein the convex surface features are selected from the group consisting of: round shaped protrusions, bumps, nubs, ridges, and combinations thereof.

13 . A friction-weld assembly, comprising:
a first polymeric component comprising a first weld surface defining a first shape; and a second polymeric component comprising a second weld surface defining a second shape, wherein one of the first shape or the second shape is convex, while the other of the first shape or the second shape is concave, wherein the first shape and the second shape are distinct from and non-complementary with respect to one another; and a friction weld joint formed between the first weld surface and the second weld surface, wherein at least one of the first weld surface or the second weld surface has a surface area corresponding to the friction weld joint of greater than or equal to about 3,000 mm 2 (about 4.7 in 2 ), and at least one of the first polymeric component or the second polymeric component remains stationary on a fixed tool, while the other of the first polymeric component or the second polymeric component is rotatable on a rotating tool during friction welding that forms the friction weld joint between the first weld surface and the second weld surface.

14 . The friction-weld assembly of claim 13 , wherein at least one of the first polymeric component or the second polymeric component is formed from a composite material comprising a thermoplastic polymer and a reinforcement material.

15 . The friction-weld assembly of claim 13 , wherein the first shape and the second shape are substantially round shapes.

16 . The friction-weld assembly of claim 13 , wherein the first shape is a hemispherical shape and the second shape is an ellipsoidal shape.

17 . The friction-weld assembly of claim 13 , wherein the surface area is greater than or equal to about 3,225 mm 2 (about 5 in 2 ) to less than or equal to about 16,200 mm 2 (about 25.1 in 2 ).

18 . The friction-weld assembly of claim 13 , wherein the surface area is greater than or equal to about 6,500 mm 2 (about 10 in 2 ) to less than or equal to about 16,200 mm 2 (about 25.1 in 2 ).

19 . The friction-weld assembly of claim 13 , wherein at least one of the first weld surface or the second weld surface has a plurality of grooves formed therein.

20 . The friction-weld assembly of claim 13 , wherein at least one of the first weld surface or the second weld surface has a plurality of convex surface features that serve as energy directors, wherein the convex surface features are selected from the group consisting of: round shaped protrusions, bumps, nubs, ridges, and combinations thereof.

21 . A method of spin-welding, comprising:
rotating a first polymeric component having a first weld surface defining a first shape at a speed of less than or equal to about 3,500 revolutions per minute (rpm); and contacting the first weld surface of the first polymeric component with a second weld surface of a second polymeric component that is held stationary while the first polymeric component rotates to create a weld joint between the first polymeric component and the second polymeric component, wherein one of the first weld surface of the first polymeric component or the second weld surface of the second polymeric component defines a concave region, while the other of the first weld surface or the second weld surface defines a convex region.

22 . The method of claim 21 , wherein the contacting occurs under an applied pressure of greater than or equal to about 1 MPa to less than or equal to about 4 MPa.

23 . The method of claim 21 , wherein the rotating and the contacting occur concurrently in either a constant speed spin-welding process or a variable speed spin-welding process.

24 . The method of claim 23 , wherein the rotating occurs at a speed ranging from greater than or equal to about 200 rpm to less than or equal to about 3,500 rpm.

25 . The method of claim 21 , wherein th

Assignees

• Gm Global Tech Operations Inc
• Teijin Ltd

Inventors

• Rousseau Ingrid A
• Konagai Yuhei
• Yagi Yutaka

Classifications

• B29C65/0672 Primary

  Spin welding · CPC title

• B29L2031/3055

  Cars · CPC title

• B29C65/0618

  Linear · CPC title

• B29C65/069

  the welding tool cooperating with specially formed features of at least one of the parts to be joined, e.g. cooperating with holes or ribs of at least one of the parts to be joined · CPC title

• B29C66/301

  Three-dimensional joints, i.e. the joined area being substantially non-flat (B29C66/5223, B29C66/5224, B29C66/5225 take precedence) · CPC title