Resistive Implant Welding of Thermoplastic Materials with Butt Joints

Abstract

A method for forming butt joints between thermoplastic members by resistive implant welding. A tongue is formed on one member to be joined and a complementary groove is formed in the other member. A resistive implant is placed between the tongue and the groove which are then pressed together by an applied pressure. An electric current is run through the resistive implant to melt a portion of the thermoplastic material of both the tongue and groove, and the melted plastic intermingles through the implant. When the electric current is removed, the plastic cools, forming a weld.

1 . An assembly connected together through the use of resistive implant welding, comprising:
 a first panel;   a groove formed in a portion of said first panel;   a second panel;   a tongue portion formed on a portion of said first panel, said tongue portion complementary in shape in relation to said groove; and   a resistive implant operable for being substantially disposed within said groove such that when said tongue portion is positioned in said groove, said resistive implant is positioned between said tongue portion and said groove, and a current is applied to said resistive implant, generating heat to join said tongue portion and said groove, thereby joining said first panel to said second panel.   
     
     
         2 . The assembly connected together through the use of resistive implant welding of  claim 1 , further comprising:
 a notch extending along and formed on a portion of said first panel, said notch being substantially parallel to said groove formed in a portion of said first panel; and   a flange extending along said second panel, said flange being complementary in shape to said notch such that when said first panel is joined to said second panel, said flange will be engaged with said notch.   
     
     
         3 . The assembly connected together through the use of resistive implant welding of  claim 1 , further comprising:
 at least one support member formed on a portion of said second panel; and   at least one slot formed between said at least one support member and said tongue portion, said at least one slot abutting a rear outer surface of said groove when said tongue portion is disposed in said groove.   
     
     
         4 . The assembly connected together through the use of resistive implant welding of  claim 3 , wherein said at least one support member is operable for preventing a bending moment about said groove and said tongue when said tongue is disposed in said groove. 
     
     
         5 . The assembly connected together through the use of resistive implant welding of  claim 1 , wherein pressure is applied to said first panel and said second panel as said resistive implant is heated to facilitate said first panel being joined with said second panel. 
     
     
         6 . The assembly connected together through the use of resistive implant welding of  claim 1 , said resistive implant further comprising a wire mesh. 
     
     
         7 . The assembly connected together through the use of resistive implant welding of  claim 6 , said wire mesh further comprising wires of substantially 0.009 inches in diameter. 
     
     
         8 . The assembly connected together through the use of resistive implant welding of  claim 6 , said wire mesh further comprising a plain weave of approximately sixteen wires per inch. 
     
     
         9 . The assembly connected together through the use of resistive implant welding of  claim 1 , wherein as a current is applied to said resistive implant, a portion of said groove will melt and a portion of said tongue portion will melt, and when said groove and said tongue portion are allowed to cool, said tongue portion will be joined to said groove. 
     
     
         10 . An assembly connected together through the use of resistive implant welding comprising:
 a first panel;   a groove formed in a portion of said first panel;   a notch formed in said first panel, said notch extending along said first panel and is substantially parallel to said groove;   a second panel;   a tongue portion formed in a portion of said second panel, said tongue portion complementary in shape to, and operable for being positioned in, said groove;   a flange formed on said second panel and complementary in shape to said notch, said flange being operable to be engaged with said notch when said tongue portion is positioned in said groove; and   a resistive implant operable for being positioned in said groove and in contact with said tongue portion when said tongue portion is positioned in said groove such that when a current is applied to said resistive implant, heat is generated, causing a portion of said tongue portion to melt, and a portion of said groove to melt, and a melted portion of said tongue portion will join a melted portion of said tongue portion after said tongue portion and said groove are allowed to cool.   
     
     
         11 . The assembly connected together through the use of resistive implant welding of  claim 10 , further comprising:
 at least one support member formed on a portion of and extending away from said second panel; and   at least one slot formed between said at least one support member and said tongue portion, said at least one slot operable for receiving an outer surface of said groove.   
     
     
         12 . The assembly connected together through the use of resistive implant welding of  claim 11 , wherein said at least one support member is operable for preventing a bending moment about said groove and said tongue when said tongue is disposed in said groove. 
     
     
         13 . The assembly connected together through the use of resistive implant welding of  claim 10 , wherein as said current is applied to said resistive implant, a pressure is applied to said first panel and said second panel, further joining said first panel to said second panel. 
     
     
         14 . The assembly connected together through the use of resistive implant welding of  claim 10 , said resistive implant further comprising a wire mesh configured as a plain weave of approximately sixteen wires per inch. 
     
     
         15 . The assembly connected together through the use of resistive implant welding of  claim 14  said wire mesh further comprising wires of substantially 0.009 inches in diameter. 
     
     
         16 . The assembly connected together through the use of resistive implant welding of  claim 10 , wherein as a current is applied to said resistive implant, said melted portion of said tongue portion and said melted portion of said groove will interface through said resistive implant. 
     
     
         17 . A method of forming a welded butt joint between first and second thermoplastic components, the method comprising the steps of:
 providing a first thermoplastic component;   providing a second thermoplastic component to be joined with said first thermoplastic component;   providing a resistive implant operable for facilitating the joining of said first thermoplastic component to said second thermoplastic component;   forming a groove along an edge of said first thermoplastic component;   forming a tongue along an edge of said second thermoplastic component;   inserting said tongue into said groove with said resistive implant located therebetween;   applying pressure to said first thermoplastic component and said second thermoplastic component to urge said tongue into said groove while applying an electric current to said resistive implant for a pre-selected time to melt a portion of said thermoplastic material of said tongue and said groove; and   removing the electric current and allowing the melted thermoplastic material to resolidify while maintaining the pressure to form a welded butt joint between said first thermoplastic component and said second thermoplastic component.   
     
     
         18 . The method of forming a welded butt joint between first and second thermoplastic components of  claim 17 , further comprising the steps of:
 forming a notch disposed along said first thermoplastic component, such that said notch is substantially parallel to said groove formed in said first thermoplastic component;   forming a flange on a portion of said second thermoplastic component; and   positioning said flange adjacent to said notch when said tongue is disposed in said groove.   
     
     
         19 . The method of forming a welded butt joint between first and second thermoplastic components of  claim 17 , further comprising the steps of:
 forming at least one support member on said second thermoplastic component in proximity to said tongue;   forming at least one slot between a portion of said at least one support member and said tongue; and   abutting said at least one slot to a rear outer surface of said groove when said tongue is disposed in said groove.   
     
     
         20 . The method of forming a welded butt joint between first and second thermoplastic components of  claim 17 , further comprising the steps of said at least one support member preventing a bending moment about said groove and said tongue when said tongue is disposed in said groove. 
     
     
         21 . The method of forming a welded butt joint between first and second thermoplastic components of  claim 17 , further comprising the steps of forming said resistive implant from a wire mesh. 
     
     
         22 . The method of forming a welded butt joint between first and second thermoplastic components of  claim 21 , further comprising the steps of forming said wire mesh from wires of substantially 0.009 inches in diameter. 
     
     
         23 . The method of forming a welded butt joint between first and second thermoplastic components of  claim 21 , further comprising the steps of forming said wire mesh from a plain weave of sixteen wires per inch.