Dielectric welding methods

Abstract

Dielectric welding apparatus has opposed electrodes that can be engaged on either side of a product to be welded and a dielectric welding power supply that supplies welding potentials to the electrodes. The apparatus includes electrically insulating buffer material adjacent to at least one of the electrodes. A recess formed in a surface of the buffer material receives an end of an electrically-conductive member in the product. The buffer material prevents arcing between the electrodes and the electrically-conductive member.

1 . A method for dielectric welding of a product comprising first and second layers and an electrically-conductive member attached to at least the first layer, the method comprising: 
 providing a first electrode;    placing the first layer adjacent to the first electrode with the electrically-conductive member projecting into a recess in a buffer material adjacent to the first electrode and the second layer adjacent to the first layer on its side away from the first electrode;    compressing the first and second layers between the first electrode and a second electrode complementary to the first electrode;    applying a high frequency welding potential between the first and second electrodes for a time sufficient to cause the first and second layers to fuse in their portions between the first and second electrodes.    
   
   
       2 . A method according to  claim 1  wherein at least one of the electrodes is in an electrode assembly having a recessed portion that is recessed away from the other one of the electrodes and the method comprises urging one of the layers of the product into the at least one recessed portion.  
   
   
       3 . A method according to  claim 2  wherein urging the layer of the product into the at least one recessed portion comprises applying suction to the recessed portion.  
   
   
       4 . A method according to  claim 1  comprising fusing the first and second layers along one or more linear lines of welding.  
   
   
       5 . A method according to  claim 1  wherein the electrically-conductive member is one of a plurality of electrically-conductive members and the method compresses receiving each of the plurality of electrically-conductive members in a corresponding recess in the buffer material.  
   
   
       6 . A method according to  claim 5  wherein the electrically-conducting members are arranged in an array and the corresponding recesses are arranged in a corresponding array.  
   
   
       7 . A method according to  claim 6  comprising fusing the first and second layers along a seam extending around the array of electrically-conducting members.  
   
   
       8 . A method according to  claim 1  comprising fusing the first and second layers along a seam extending around the electrically-conducting member.  
   
   
       9 . A method according to  claim 1  comprising, after applying the welding potential, waiting for a cooling interval and then separating the first and second electrodes.  
   
   
       10 . A method according to  claim 1  comprising fusing the first and second layers at one or more isolated spots.  
   
   
       11 . A method according to  claim 10  comprising fusing the first and second layers along a peripheral seam extending around the electrically-conductive member and the one or more isolated spots.  
   
   
       12 . A method according to  claim 1  wherein the electrically-conductive member is one of a plurality of electrically-conductive members of the product and the method compresses seating each of the plurality of electrically-conductive members in a corresponding recess in the buffer material before compressing the first and second layers.  
   
   
       13 . A method according to  claim 1  comprising urging one of the first and second layers into a groove in the buffer material to provide a passage in the product.  
   
   
       14 . A method according to  claim 13  wherein one end of the electrically-conductive member is in the passage.  
   
   
       15 . A method according to  claim 13  wherein urging the one of the first and second layers into the groove comprises applying suction to the groove.  
   
   
       16 . A method according to  claim 1  wherein the electrically-conductive member penetrates one of the first and second layers.  
   
   
       17 . A method according to  claim 16  wherein one end of the electrically-conductive member is between the first and second layers during compressing the first and second layers.  
   
   
       18 . A method according to  claim 1  wherein the electrically-conductive member projects into both the recess in the buffer material adjacent to the first electrode and another recess in a buffer material adjacent to the second electrode.  
   
   
       19 . A method for dielectric welding of a product comprising a plurality of layers of a dielectric material and an electrically-conductive member passing through at least one layer of the plurality of layers, the method comprising: 
 placing the plurality of layers between first and second electrodes with the electrically-conductive member projecting into a recess in an electrically non-conducting buffer material adjacent to one of the first and second electrodes;    compressing the plurality of layers between the first and second electrodes; and,    applying a high frequency welding potential between the first and second electrodes for a time sufficient to cause the plurality of layers to fuse in their portions between the first and second electrodes.    
   
   
       20 . A method according to  claim 19  wherein at least one of the electrodes is in an electrode assembly having a recessed portion that is recessed away from the other one of the electrodes and the method comprises urging one of the plurality of layers into the at least one recessed portion.