Abstrict A method of constructing a desiccant pot by trapping a spun-bonded
low density membrane between two separate parts constituting either
the pot lid or the pot body, these two separate parts being made
of high density plastic, and then fusing the membrane and the separate
parts together, in which one of the separate parts has upon its
touching surface an energy directing protrusion, arranged such that
when the three components are assembled so that the two separate
body and lid parts are pressed together with the membrane between,
the energy directing protrusion extends from one touching surface
to the other to space them slightly apart.
Claims 1. A method of constructing a desiccant pot by trapping a low density
membrane of spun bonded plastics between opposed touching surfaces
of two separate parts constituting the pot lid and the pot body,
these two separate parts being made of high density plastic, and
then fusing the membrane and the separate parts together by ultrasonic
welding, characterized by providing one of the separate parts with
a fine protuberance in the form of one or more ridges or points
extending from its touching surface towards the touching surface
of the other separate part to space the touching surfaces slightly
apart, and pressing the two parts together with the membrane trapped
between the touching surfaces so that the membrane is compressed
at the point of contact with the protuberance thereby increasing
its density at the point such that, at the time of ultrasonic welding,
the protuberance acts as an energy directing protrusion, and the
ultrasonic vibrations pass from the protuberance on the one part
through the membrane at the point where it is compressed to increase
its density to the other part.
2. (canceled)
3. A method according to claim 1 in which, the energy directing
protrusion forms a continuous ridge around the periphery said one
part.
4. A method according to claim 1 in which, the energy directing
protrusion comprises a series of discrete protrusions arranged around
the periphery of said one part.
5. A method according to claim 1 in which the energy directing
protrusion projects from the touching surface a distance of between
0.5 and 0.7 mm.
6. A method according to claim 1 in which the point or edge of
the energy directing protrusion is as sharp as possible to minimise
the cross-sectional area of the tip of the protrusion.
7. A method according to claim 6 in which the body is a tubular
component and the energy directing protrusion is a sharp knife like
edge at the end of the tubular body component.
8. A method according to claim 7 in which the energy directing
protrusion is formed by moulding a chamfer to the outside edge of
the tube wall.
9. A method according to claim 8 in which the angle of chamfer
is of the order of 60.degree..
10. A method according to claim 1 in which the energy directing
protrusion is arranged such that it bears against a peripheral area
of the membrane.
11. A method according to claim 1 in which the separate parts
of the pot body and pot lid are of a high density polyethylene.
12-14. (canceled)
15. A method according to claim 1 in which the pot body has first
and second ends and each end is provided with a pot lid and a membrane
trapped between the pot lid and the adjacent end of the body.
Description [0001] This invention relates to desiccant stoppers for a wide
range of containers, and concerns in particular plastic stoppers,
comprising a breathable plastic membrane to absorb any free moisture
(or odours and the like) in the container.
[0002] Desiccant stoppers are used to control the moisture or odour
vapour levels of air, within a sealed container, such as a bottle,
jar, bag or box, and to control the closed atmosphere to the benefit
of sensitive products such as pharmaceuticals packaged within. They
are produced in a number of sizes and types relevant to the size
and nature of the container and the content to be protected. They
must be non-toxic, resistant to water, strong, sterile, and able
to provide a microbial barrier. They must also be dust-free, and
dust-proof.
[0003] The present invention relates to the type of desiccant stopper
described in WO 02/038465 which comprise a suitably-sized capsule,
rather like a small pot or jar, as the desiccant holder, and after
this has been filled with the chosen desiccant it is capped with
either a porous-type material wad (such as a thin disc of cardboard)
crimped into place, or capped with a moulded plastic lid with cast-in
perforations.
[0004] Dependent upon their end use, desiccant stoppers can be
filled with a wide variety of desiccant-material content. In the
event that they are required to control moisture, suitable absorbent
materials are silica-gel, or molecular sieve, while for the control
of odours, granulated carbon is used. Some devices can be used to
control the level of a specific gas within a sealed container where
the gas might have an ill effect upon the contents. One such gas
is oxygen; oxygenation can often lead to serious content deterioration.
In some instances, a mixture of several different materials, and
types of material, will be formulated and used, and there are a
number of proprietary brands of admixtures on the market.
[0005] Regardless of their content, these stoppers are generally
referred to as "desiccant stoppers"; their use is extensive
within Pharmaceutical, Veterinary, Foodstuffs, and Electronics goods
packaging.
[0006] WO 02/038465 discloses a method for the production of such
a stopper, in which method a fibrous fabric sheet is held in place
between the two relevant parts--the stopper body and the lid--and
these two are then fused together and to the sheet so that on cooling
and solidifying they form a solid, integral plastic supporting frame
around the sheet fused thereinto. The term "fused" as
used herein means that the materials of the body and lid and the
materials of the sheet have become one integral body, as though
the entire stopper had been cast in a single piece. Thus, the body
and lid materials are not merely attached to either side of the
fibrous sheet, and do not even merely extend integrally through
the sheet, but are instead actually integral with--have become one
with--the sheet.
[0007] The fibrous fabric sheet is that spun-bonded breathable
plastic (Low Density Polyethylene, or LDPE) material known as TYVEK
HBD 1059 and manufactured by Dupont
[0008] Spun-bonded materials made from LDPE or the like--referred
to hereinafter for convenience simply as "spun-bonded plastics"--are
immensely strong, and will not tear. They will bond with other plastic
parts of similar plastic specification providing temperature profiles
are strictly observed (being extremely thin, typically as little
as 0.15 mm thick, they are easily performance-impaired, even destroyed,
by the application of too much heat).
[0009] Spun-bonded plastics, and particularly the TYVEK types of
material, are most suitable to act as a permeable membrane for desiccant
stoppers due to the superb transfer through them of moisture and
odour vapours. The microporosity of the material controls dust emission,
and the high tear strength and puncture resistance is perfect for
ensuring the integrity of the final finished article. Another example
of such a spun-bonded plastics is that material available under
the name TEIJIN, and manufactured by Unisel (now amalgamated with
Dupont).
[0010] The method might be said to be characterised by the manner
in which the membrane and body/lid parts are disposed to enable
the required sonic fusing to take place. A high density pot/lid
plastic can most reliably be fused with a low density membrane plastic
provided that the pot/lid make physical contact with each other,
to transmit the vibrations and make them melt, with the membrane
retained in a recess between the two such that it, too, melts--to
become fused integrally with the pot/lid--but only at its very outermost
edge.
[0011] According to the invention, there is provided a method of
constructing a desiccant pot by trapping a spun-bonded low density
membrane between two separate parts constituting either the pot
lid or the pot body, these two separate parts being made of high
density plastic, and then fusing the membrane and the separate parts
together, in which one of the separate parts has upon its touching
surface an energy directing protrusion, arranged such that when
the three components are assembled so that the two separate body
and lid parts are pressed together with the membrane between, the
energy directing protrusion extends from one touching surface to
the other to space them slightly apart.
[0012] Thus in this method of ultrasonic welding, when joining
two or more High Density plastic parts, (end cap(s) and body) and
a Low Density plastic spun-bonded material membrane, the high density
plastic components are profiled, so that at least one of those components
has an energy director ridge(s) or point(s) designed into the component.
[0013] An energy director profile is a section of the moulding
which is situated at the intended point of an interface, when that
interface will marry with another separate interfacing component.
It is a fine protuberance, either a ridge(s) or point(s) standing
higher than the underlying land area from which it protrudes.
[0014] Thus the energy directing protrusion may form a continuous
ridge around the periphery of one of the parts or could comprise
a series of discrete protrusions arranged around the periphery of
the part. Preferably the distance the protrusion projects from the
touching surface is between 0.5 to 0.7 mm.
[0015] When the parts to be welded are placed together and are
touching, the height of the energy directing ridge(s) or point(s)
separates the two flat interface surface areas, which can only then
initially interface across the/those highest points.
[0016] The effect of the energy directing protrusion is to do exactly
as the term implies, to direct high intensity friction to an exact
position, designed as a sharp edge(s), or a sharp point(s). Preferably
the point or edge is designed to be as sharp as possible--with the
cross-sectional area of the tip of the protrusion being minimised.
[0017] Because that sharp edge(s) or sharp point(s) is the first
touching point of interface with the other component to which it
is to be joined, and whilst it is subjected to a holding pressure,
the force applied to hold the components together is concentrated
at that point(s), in consequence, all of the energy released at
the moment of ultrasonic vibration is also directed to that point(s).
[0018] The vibratory action applied, causes intense frictional
heat at those first interfacing points. This spreads deeply into
secondary interface areas now brought together by the collapse and
dispersal of the energy director profile(s). The areas of contact
become molten and fuse together. The result is a strong weld.
[0019] The stopper is pot-like--that is, it is in the shape of
a small container (perhaps 0.6 in [15 mm] across, and 0.8 in [20
mm] deep) for holding in use the desiccant (or other) material contained
by the stopper. The stopper can be of any convenient cross-section,
but a tubular section is generally most suitable, fitting into most
containers of pills or the like.
[0020] In the case of this application, the energy director is
a sharp knife like edge, at the end(s) of the tubular body component.
[0021] By moulding a chamfer to the outside edge of the tube wall,
a knife like edge around the entire periphery of the end(s) of the
capsule body is formed to produce a suitable energy director. In
this case it is preferred that the angle of chamfer is of the order
of 60.degree..
[0022] Preferably the energy directing protrusion is arranged such
that it bears against a peripheral area of the membrane.
[0023] The stopper ends up as a one-piece (integral) object, but
for manufacturing purposes it is formed from at least three pieces,
namely a body portion, a lid (or cap) portion that fits into the
body portion, and a membrane portion that is placed between and
fuses to the body and lid portions. The lid (or cap) portion is
conveniently a simple one-piece object that fits into the body portion,
the membrane portion being between and fused to the body and lid
portions.
[0024] Of course, although the body portion may be formed with
its other, non-lid end, already closed, it is also possible to have
the body portion as an open-ended central ring portion, with a cap/lid
at each end.
[0025] The flat bottom surface of the body portion, and the flat
top surface of the (or each) lid/cap portion, provide the two end
faces of the stopper; one or both of these is made from the fibrous
fabric sheet of plastics material fused sealingly around its periphery
to the main/side parts--the wall portions--of the body or lid appropriately.
[0026] For the stopper a typical preferred material is a High density
Polyethylene (HDPE), and examples of this are that material known
as LADENE (an HDPE manufactured by SABIC Marketing Ltd. Saudi Arabia
and distributed in the UK by ALBI Ltd., of Knutsford. Cheshire),
and the material sold by BP Chemicals as "BP High Density Polyethylene"
(and distributed in the UK by Distropol Ltd., of Chertsey. Surrey).
Each of these grades of HDPE are FDA approved, and are also suitable
for near field and far field ultrasonic welding.
[0027] Alternatively high melt polypropylenes can be used.
[0028] For the membrane the preferred material is, as intimated
above, that known as Perfecseal HBD 1059B TYVEK, manufactured by
Dupont. This is a low density polyethylene. Dupont produce a range
of materials under the Trademark TYVEK, each of which have specific
end uses. Many of the products from this range are suitable for
the purposes which are here described. Another suitable material
is that available under the name TEIJIN, and manufactured by Unisel.
The principal purposes of these types of materials are as breathable
fabric membranes used to construct bags or sachets, or to cover
plastic or foil tray-like containers, to which they are fastened
using conventional heat sealing techniques. For best results a large
area of contact is required between the two materials which are
to be joined.
[0029] At the time of assembly of the components, and when they
are correctly positioned, each to each other, the positions are
as described:
[0030] a) The Tyvek membrane is placed into the end cap, where
it is retained being an interference fit.
[0031] b) The capsule body is then placed into the open end of
the end cap(s) and pressed into place.
[0032] c) The assembled components are then as a sandwich with
the Low Density plastic spun-bonded membrane trapped firmly between
the two High Density plastic components, (Being the end cap(s) and
the body of the capsule.) The energy director profile is in direct
contact with the spun-bonded membrane material, and is held in position
under pressure.
[0033] At the time the ultrasonic welding process is applied, the
parts are forced together by the actuator, which applies a holding
pressure before the ultrasonic vibratory welding period begins.
[0034] The sharp knife-like edge of the High Density tubular body
of the capsule, is forced against the Low Density spun-bonded membrane,
situated and supported in the High Density end cap(s). The Low Density
spun-bonded membrane, typically only 0.15 mm thick, compresses at
the area of the point of contact with the High Density energy director
profile, closing the porous nature of the membrane material, substantially
increasing its density at that point. When the ultrasonic vibrations
are applied, the energy director leading edges are the first points
of interface to be agitated, and are subsequently the first areas
of interface to melt and fuse together.
[0035] The friction induced melt, progresses through the extremely
thin, (lower temperature affected) spun-bonded material, to the
high density plastic (higher melt temperature) component on the
other side of the membrane, spreads and fuses, becoming an integrated
mass, which when cooled forms a strong weld, fusing the end cap(s),
membrane and capsule body, into a solid single part.
[0036] This method relies upon the technique of sonic--that is
to say, "ultrasonic"--welding of thermoplastic parts to
fuse the body and lid parts together, embedding the membrane therewithin.
This technique is now described in more detail.
[0037] The principle of ultrasonic assembly involves the use of
high-frequency mechanical vibrations transmitted through thermoplastic
parts to generate a frictional heat build-up at an interface. The
effect of the vibrations causes intense friction between separate
but touching parts, causing the materials to heat and melt and weld/fuse
together.
[0038] This vibrational movement is effected by a vibrating component
called a "sonotrode", which is applied at right angles
to the surface of a part to be welded. The latter starts to vibrate
throughout due to a series of stationary waves, with a maximum amplitude
in the area of contact of the two parts to be joined. Ultrasonic
plastic welding techniques, have been successfully used for more
than 25 years by engineering companies within the plastics industry.
[0039] After cooling, which is rapid, a solid homogeneous weld
results between the parts of the assembly. The membrane is thus
integral with the solid plastic of the body and lid parts, and so
is inseparable therefrom. It thus provides an impermeable barrier
to the passage of microparticulate matter, preventing escape of
the chemical ingredients of the capsule, and so making the stopper
unit both dust-free and dust-proof. The membrane is presented as
a window to the stopper, allowing unimpeded passage of moisture
or odour vapours, in either direction, through the microporous material.
[0040] One important factor relevant to the use of sonic welding
for this purpose is the compatibility of the body/lid material and
the membrane material. The preferred choice for the spun-bonded
plastics membrane material is TYVEK, which is a Low Density Polyethylene
(LDPE) product. It might then be thought that a low density material,
and specifically a low density polyethylene, should also be used
for the body/lid material. However, it transpires that low density
materials such as this are in fact rather difficult to weld sonically.
The reason seems to be that they are too "soft", and vibrations
generated in one part tend to get damped out too easily, and are
not transmitted through to the other part, so that the two do not
move against each other in a manner sufficient to produce fraction
and heat--and without that heat, of course, they do not melt, and
so do not weld/fuse together.
[0041] Another crucial factor is temperature. Spun-bonded plastics
such as TYVEK are extremely thin, and are prone to the effect of
high temperatures which causes them to shrivel. Exposure to temperature
in excess of 125.degree. C. renders TYVEK useless, as the matrix
which provides the permeability melts, collapses, and congeals into
an impermeable structure. The melt point at which HDPE becomes molten,
is approximately 150.degree. C.; this temperature is higher than
the destruction point temperature of TYVEK, so it might be thought
that fusing a low density membrane to a high density stopper body/lid
would be impossible. However, while merely fusing a sheet of an
LDPE material such as TYVEK to a body of an HDPE material is indeed
fraught with problems, these seem to be banished in the case where
the low density sheet is trapped around its periphery between two
high density surfaces; surprisingly, placing the low density membrane
between two high density parts in the form of a sandwich does in
fact produce a reliable fusion of the components. Accordingly, the
use of the energy directing protrusion reduces this problem of high
temperature upon the former, as the melt temperature of the high
density parts is contained local to the fusion point of the two,
leaving the greater expanse of the low density membrane completely
unaffected.
[0042] The success of this technique depends entirely on the ability
of the materials to propagate vibrations without damping them; excellent
results can be obtained with suitable thermoplastic rigid materials
with a high modulus of elasticity. The method permits the welding
of objects of very complex design with a sonotrode which is very
simple in form.
[0043] As referred to hereinbefore, the stiffness of the polymer
to be welded will influence its ability to transmit the ultrasonic
energy to the joint interface. Generally the stiffer a material
the better its transmission capability. It is usually not possible
to weld materials of different types by ultrasonics, due to the
differences in fusion temperature. If the macromolecular structure
is not the same for both materials, it will prevent interpenetration.
[0044] During the period of time that the ultrasonic vibration
welding method is applied, a degree of pressure must be exerted
to hold the components together. Each high density component must
be in contact with the other in order that the ultrasonic vibrations
can be transmitted through the component nearest the sonotrode.
Moreover, each component should be designed to provide a sufficient
surface area to be in firm contact with an equal surface area on
the part to which it is to be welded. The fusion takes place at
the interface of the two surfaces. Each component is held together
by applied pressure at the point(s) at which they become welded.
[0045] As the ultrasonic vibration is applied, and with the simultaneous
application of pressure holding the combination together, the ultrasonic
vibration passes through one of the high density parts and on into
the second, causing friction effects at their interface. The friction
produces heat sufficient to melt the plastic--both of the body/lid
(the two contacting high density components) and the membrane (the
low density component), allowing the plastics to flow, and by the
pressure being exerted upon the two parts forcing them together,
fuses all three into an inseparable bond. Thus, the membrane is
securely fused to the container, being embedded at all of its outer
edges, and at any interface with the capsule body and/or the retaining
end cap(s). The edges of the membrane and some of the surface membrane
material close to the edges is penetrated by the flowing plastic,
over moulded and through moulded by the molten plastic whilst liquid
and under pressure. The molten plastic of the body end cap(s) fuses
to the spun filaments of the fibrous spun-bonded plastics material
which is the membrane, and as it cools solidifies and forms a solid
plastic frame around and through the membrane. The spun-bonded plastics
material itself is also part welded in the operation, as some degree
of sonic vibration is effective between the low density membrane
and the high density capsule body; this further enhances the fusion
bond between the body and lid high density components.
[0046] The following points should be borne in mind when using
sonic welding.
[0047] 1. The cap/lid is to be welded to the body, and while this
could be a butt weld it is preferred to chamfer each abutting face
in a matching manner, to form a larger weld surface. Specifically,
the edge of the side wall of the cap(s) is moulded to a form recommended
as a correct interface profile for ultrasonic welding.
[0048] 2. The edge of the side wall of the body is correspondingly
moulded to a form recommended as a correct interface profile for
ultrasonic welding, but also incorporates a section which, when
the two plastic components (body & cap) are placed together
with the TYVEK type material also in place, acts as a snap fit to
temporarily secure the components together, with the underside of
the cap in close proximity with the uppermost side of the top edge
of the inserted profiled wall of the plastic body.
[0049] 3. When a membrane window is required at both ends of the
stopper, the process described is repeated at the opposite end of
the container, which is moulded to suit.
[0050] 4. It is normally most convenient to assemble the stopper
one end at a time, in an upright position, with the end cap placed
on top at the time of assembly and ultrasonic welding.
[0051] 5. Once correctly positioned, with the membrane held therebetween,
the body/lid mouldings are ultrasonically welded together to form
an integrally-joined capsule. The or each porous membrane is encapsulated
within the previously separate components, held in place by the
weld between the body and the relevant cap or end.
[0052] In this way the fabric sheet--the spun-bonded plastics TYVEK-type
material--is fused around its periphery to the material forming
the stopper body/lid combination. The membrane is thus presented
as a window to the stopper container's body or lid portion, and
thus in use allows unimpeded ingress by moisture or odour vapours.
Moreover, reinforced as it is by the plastic frame in which it is
totally suspended, the membrane acts as a structural form securing
the contents of the stopper from loss or damage.
[0053] As can be inferred from what has been said above, there
is a choice of spun-bonded plastics material membrane at one or
more positions on the desiccant stopper. Typically the position
of a single membrane could be at the end of a stopper, whilst a
stopper with two membranes could have them situated one at either
end (the purpose of two membranes would be to allow a faster ingress
of vapours).
[0054] And as also noted above, in the case of a stopper with one
membrane only, it will be seen that there is a requirement for two
parts. One is the body portion--the receptacle into which the desiccant
is placed, while the other is the lid portion. Either may carry
the membrane as its end wall, but usually it is more convenient
to use the lid for this.
[0055] When two membranes are required within a single desiccant
stopper the unit can be constructed in a variety of ways. One preferred
way is to manufacture the unit in three or more parts, comprising
two separate cap/lid-like end parts and one (or more) central body
part open at both ends. The end parts--each identical in manufacture--carry
the membrane as a tight fit, and each is welded separately to the
central body part to form the complete container (into which the
fill content is placed before attachment of the second "lid"
end to complete the structure).
[0056] One further advantage of the described method of assembly
is the ability to pre-prepare the components ready for use. The
spun-bonded plastics membrane discs can be pre-cut and inserted
into the cap ends where they are held fast being an interference
fit, before being fitted to the container body. Similarly the body
of the capsule can be pre-assembled to one cap end with the spun-bonded
plastics membrane already inserted, and sonic welded together, as
a pre-form produced for the filling machinery.
[0057] Where the several parts of the stopper--the body and one
or more end cap/lid--are manufactured separately (and then joined
together) it is of course possible to give them different colours.
This may be used, if wished, for identification purposes--to indicate,
perhaps, either what is inside the stopper (what desiccant is used)
or what the stopper is to be employed with (what materials or articles
it can be utilised to keep dry, say).
[0058] The area of membrane left exposed as a window of permeable
material to the container, is not affected in any detrimental way,
and its efficacy is not impaired. The design allows ingress or egress
of gaseous vapours through the membrane, to or from the encapsulated
chemical materials contained within the capsule, but prevents leakage
of the contents, due to the high integrity and reliability of the
seal, caused by the fusion of each of the components to become one
integral part.
[0059] Ultrasonic Welding
[0060] The Process
[0061] The process of ultrasonic welding as here applied utilises
the ability of thermoplastic resin to form a welded joint at the
interface of two parts when, by generating heat at the interface
by applying directed mechanical vibratory energy, the plastic melts,
and becomes fluid. Once the resin is molten at the joint, it flows
at the point(s) of contact, and if a force is applied during the
time of the heat generation the parts are pressed and fused together
to form an inseparable homogeneous link. This technique is fast,
efficient, non-contaminating, and does not require consumables.
[0062] Ultrasonic assembly systems are available in several levels
of frequency, and can be controlled in terms of time, energy, energy
compensation, distance and force applied. Suitable frequencies for
a system capable of the type of assembly required in this invention
are around 20 kHz, rated at between 1100 and 3300 Watts.
[0063] The Equipment
[0064] Branson Applied Technologies Group, of Hayes, Middlesex
manufacture a wide range of ultrasonic vibratory welding machines.
Ultrasonic Engineering Ltd, of Singapore Road, London manufacture
a specialist range of ultrasonic vibratory welding machines.
[0065] A typical ultrasonic vibratory welding system consists of
four essential components.
[0066] 1) The power supply--electronically converts the 50 Hz mains
supply to the required 20 kHz operating frequency.
[0067] 2) The converter--also driven from the power supply--consists
of a number of polarised piezoelectric discs which have a natural
resonance to 20 kHz. When subjected to the ultrasonic frequency
output from the power supply, the discs increase, and then decrease
their physical size, in the same time frequency as the power supply,
in other words at a speed correspondent to 20 kHz. In this way vibrations
are caused by the electrical signal being converted into mechanical
energy, and they are passed directly to the horn/(sonotrode), which
is then brought into contact with the work piece for a determined
time and set pressure, to produce intense friction and a subsequent
weld in a very efficient and controlled way.
[0068] 3) Acoustic tooling--used to couple, and boost energy from
the converter to the parts to be welded. The tooling is manufactured
from either titanium or aluminium alloy and is tuned to resonate
at the same frequency as the converter. The amplitude, or vibration
movements, from the converter alone is often insufficient to generate
a weld, so acoustic tooling, or horns/(sonotrodes) as they are called,
are installed to amplify the amplitude to a corrected value. In
order to obtain the correct resonant frequency, and a magnification
of amplitude to the correct level, to provide and transfer uniform
movement to the working face of the horn/(sonotrode), great care
is necessary to determine the correct design of shape and mass of
the tooling, and the material from which it is manufactured.
[0069] Acoustic tooling is made from two parts: a booster horn
which modifies the amplitude from the converter to the correct value
for the specific application; and the work horn/(sonotrode) designed
for the job. The work horn/(sonotrode) is configured to suit the
geometry of the parts to be welded.
[0070] The ideal situation is to provide a flat face for the work
horn/(sonotrode) to channel energy into the parts.
[0071] Operating the Method
[0072] Vibratory energy under pressure is passed into the work
piece by the acoustic tool or horn which is brought into contact
with one of the parts to be welded. Vibratory energy is passed through
the work pieces resulting in localised frictional heating at the
joint interface surfaces, causing the plastic to melt. On termination
of the energy input, the plastic solidifies forming a high strength
molecular bond. The weld is achieved in a time of typically less
than one second, the heat generated is local to the joint area.
[0073] 4) The actuator--a simple, pneumatically controlled device
which brings the acoustic tooling into contact with the work piece.
It must be of rigid construction, able to consistently present the
welding horn/(sonotrode) accurately onto the work piece, and maintain
a set pressure for the duration of the weld time.
[0074] Usually it is mounted on an compressed air driven cylinder,
which has controlled movement up and down, or through other single
axis directions.
[0075] Efficiency
[0076] Two factors which establish a thermoplastic resin's ability
to weld, are how well it transmits energy from the welding horn
to the joint interface, and how good is its coefficient of friction
and melt temperature.
[0077] For ultrasonic welding purposes, resins are divided into
two major groups, Amorphous or Crystalline. These groupings refer
to the molecular structure of the plastic. In the solid state, amorphous
plastics have no ordered structure. This enhances the materials
ability to transmit energy.
[0078] Amorphous materials do not have a precise melt point. With
heat they become soft before they then become a viscous liquid.
This progressive melt to molten state aids the welding process by
allowing at the point of interface, fusion of the liquid plastic.
The process is easy to control.
[0079] Far and Near Field Welding
[0080] Clearly distance to the joint line from the horn land area
is a critical consideration. To assist with defining a resin's ability
to transmit ultrasonics the terms "near field" and "far
field" have been adopted for defining distance of energy transmission.
These terms are generally applicable to 20 kHz operation.
[0081] Near field welding is defined as the distance between horn/(sonotrode)
and joint interface if less than 6 mm. Reasonable energy transmission
in rigid amorphous materials can be obtained over this distance.
[0082] Far field welding is defined as the distance between horn/(sonotrode)
and joint interface when greater than 6 mm.
[0083] Other Factors
[0084] Two other factors of consideration are component rigidity
and the energy route to the joint or interface.
[0085] The actuator will apply a pressure of between 20 and 80
Newtons to the parts to be welded at the time of the welding process.
The assembly must be designed to withstand such pressure during
the operation. The application of a set measure of pressure is important
to the mechanical action of the Horn/(sonotrode) at the time that
it is in contact with the plastic component(s), and it must be progressive,
as the plastic material when molten partially compresses whilst
under pressure from the actuator.
[0086] Good component design is crucial for successful welding.
In order for the process to work, energy has to be transmitted through
the components one to the other to promote a good weld, the strength
of which is determined by the depth of penetration. A weld depth
of 0.5-1.0 mm is considered sufficiently strong for the application
described.
[0087] To ensure good repeatability of weld, the settings of the
equipment should be observed and committed to record. Ultrasonic
equipment can be integrated into automated systems. Any information
relevant to weld parameters, such as time, amplitude, frequency,
energy, or distances, if available digitally from the welder equipment,
can be extracted, recorded, and stored in a database.
[0088] A desiccant stopper, in accordance with the invention, will
now be described, though by way of illustration only, with reference
to the accompanying diagrammatic Drawings (the Drawings are based
on cylindrical and circular designs, but other shapes are also suitable
for moulding) in which:
[0089] FIGS. 1A & B show in plan and in section a desiccant
stopper;
[0090] FIGS. 2a & B show in section both final and exploded
part views of the stopper;
[0091] FIG. 3 is an enlarged part section of the desiccant stopper
with the membrane omitted for clarity; and,
[0092] FIG. 4 is an enlarged part section of the desiccant stopper
illustrating the membrane in place.
[0093] FIGS. 1A & B are almost self-explanatory. They show
a desiccant stopper (generally 11) of the invention. The stopper
is tubular, and of circular section, and thus is like a small pot.
[0094] The version of stopper shown here has a tubular main body
portion (12) and two annular lid portions (13), one at each end.
Each lid 13 fits on to the body using mating recesses (14a in the
lid, 14b in the body, as shown). The top (as viewed) surface of
the lid 13 is a "window" (15) made of a porous fibrous
fabric sheet material membrane; this is shown in FIG. 1B with diagrammatic
perforations, to indicate that it is a porous sheet, but in fact
it has no visible perforations at all. All around its edge (16)
the sheet is trapped between, and integrally fused to, the lid and
the body.
[0095] In the embodiment of FIG. 1 the membrane 15 is located between
the body 12 and the lid 13. This area is shown only generally in
FIGS. 1 and 2 with the specific form shown in detail in FIGS. 3
and 4.
[0096] FIG. 2 illustrates generally the steps in manufacture and
depicts the snap fitting 17/18 between the mating body 12 and lid
13.
[0097] Both the pot lid 13 and a pot body 12 are of high density
plastic. A spun-bonded low density membrane 15 is trapped between
the lid 13 and body 12. After trapping the membrane 15 in position
the membrane 15 and the separate parts 12 13 are fused together
[0098] One of the separate parts 12 13 (in this case the pot body
12) has upon its touching surface 20 an energy directing protrusion
21 arranged such that when the three components are assembled so
that the two separate body and lid parts are pressed together with
the membrane between, the energy directing protrusion 21 extends
from one touching surface 20 to the other 22 to space them slightly
apart.
[0099] The protrusion 21 comprises a circular ridge with a sharp
edge formed by a 60.degree. chamfer 24 on the outside edge of the
wall of the pot body 12 around the periphery. The pot ridge 21 extends
between 0.5 and 0.7 mm from the touching surface 20.
[0100] At the time of assembly of the components, and when they
are correctly positioned, each to each other, the positions are
as described:
[0101] a) The Tyvek membrane 15 is placed into the end cap 13
where it is retained being an interference fit.
[0102] b) The capsule body 12 is then placed into the open end
of the end cap(s) 13 and pressed into place.
[0103] c) The assembled components are then as a sandwich with
the Low Density plastic spun-bonded membrane 15 trapped firmly between
the two High Density plastic components, (Being the end cap(s) and
the body of the capsule.) The energy director profile 21 is in direct
contact with the spun-bonded membrane material 15 and is held in
position under pressure.
[0104] At the time the ultrasonic welding process is applied, the
parts are forced together by the actuator, which applies a holding
pressure before the ultrasonic vibratory welding period begins.
[0105] The sharp knife-like edge 21 of the High Density tubular
body 12 of the capsule, is forced against the Low Density spun-bonded
membrane 15 situated and supported in the High Density end cap(s)
13. The Low Density spun-bonded membrane 15 typically only 0.15
mm thick, compresses at the area of the point of contact with the
High Density energy director profile 21 closing the porous nature
of the membrane material, substantially increasing its density at
that point. When the ultrasonic vibrations are applied, the energy
director leading edges are the first points of interface to be agitated,
and are subsequently the first areas of interface to melt and fuse
together.
[0106] The friction induced melt, progresses through the extremely
thin, (lower temperature affected) spun-bonded material, to the
high density plastic (higher melt temperature) component on the
other side of the membrane, spreads and fuses, becoming an integrated
mass, which when cooled forms a strong weld, fusing the end cap(s),
membrane and capsule body, into a solid single part.
[0107] The assembly process of the desiccant pot is divided into
six stages. For the purpose of explanation, each stage is described
as a single action, but in production, the action will be constantly
repeated. It is implied that at the completion of each single action,
at all stages, the process is repeated by command of an electronic
instruction. All stages are simultaneously active, synchronised
to repeat at the same time.
[0108] Stage 1) Plastic Injection Moulding of the Plastic Component
Parts
[0109] The body of the capsule, and the end cap(s) are produced
using modern injection moulding techniques, from High Density Polyethylene
with a melt index of 30.
[0110] Multi cavity moulds are employed to produce high quality
mouldings of each of the components required, from moulds incorporating
hot runner systems. This method has the effect of producing cosmetically
pleasing mouldings, to satisfactory dimensional tolerances, with
very little scrap or reject rate, due to the absence of sprue and
runner.
[0111] Use of a high melt material assists in the moulding cycle
time, particularly in the manufacture of thin wall, or fine detail
items. The mouldings can be produced to colour of choice.
[0112] It is known that High Density Polyethylene materials which
have a high melt index figure are also likely to be stiffer after
moulding than lower melt index materials made from the same material.
The effect of the stiffness factor in the finished components assists
the ultrasonic welding processes that follow. High Density plastic
materials respond well to ultrasonic welding processes, but weld
performance is enhanced when the stiffness of the plastic material
contributes to an improved flow path for the sonic vibrations to
the component(s) interface, which is the required point of fusion/weld.
[0113] Both that material known as LADENE and the material sold
by BP Chemicals as "BP High Density Polyethylene" are
satisfactory.
[0114] Stage 2) Preparing the Spun-Bonded Breathable LDPE Membrane
[0115] The spun-bonded breathable LDPE membrane was made from TYVEK
HBD 1059.
[0116] Tyvek is extremely strong, and is exceedingly difficult
to cut repeatedly, without the need to constantly re-sharpen the
punch tooling. A better and totally consistent method, is to use
Laser cutting techniques which do not rely on sharp edge forms to
cut.
[0117] Using a laser--typically a Carbon Dioxide Laser--to cut
material is in general well known, and needs no detailed comment
here. It is, however, well suited to adaptation as a device for
marking and cutting plastic materials, and is particularly efficient
and economic with thin film-like materials.
[0118] A suitable laser cutter is available from Alltec UK Ltd.,
of Maltby, South Yorkshire, while Laserex/Hi-Tech UK Ltd., of Rotherham,
South Yorkshire, manufacture a range of ancillary equipment essential
to Laser operation.
[0119] Tyvek type material can be procured in reel form, and can
be slit to any width required.
[0120] Tyvek is very inclined to static interference during handling,
and discs pre-cut and stored together, are prone to collect in difficult
to separate masses. Precautions are recommended to be taken to prevent
the problems that this state causes. The manufacturers recommend
a number of solutions to the problem in their literature.
[0121] One preferred method of control of the Tyvek discs whilst
being cut to size from the reel web, and to avoid the problems of
static interference (the discs stick together), is to hold the Tyvek
material prior to the time of the Laser cut with a vacuum-operated
suction cup, and then to Laser-cut around the suction pad, to the
disc size required, the Laser cut to be completed whilst the Tyvek
is held firmly in place by the suction pad. The advantage of this
method of handling is that first of all, the Tyvek disc is under
control as a single item, and is not allowed contact with other
discs, so avoiding the static which is caused when discs in multiples
are in contact with each other. Secondly, the cut disc, firmly held,
can be positioned very precisely into the presented end cap of the
capsule, at the following stage of the operation.
[0122] Thus: this method of operation is conducted by passing the
Tyvek web of material from the primary reel, over the suction cup
section of a pick-and-place pneumatically-operated dextrous robot
arm, which upon command will move up and under the Tyvek web, and
will fasten itself by suction onto the underside of the Tyvek material
prior to the Laser cut.
[0123] The Laser cutting equipment is then situated over the Tyvek
web, and cuts in a downward motion around the vacuum suction cup,
which at completion is left holding the separated disc. The robot
can now remove the disc from the path of the overhead reel by pulling
it downwards, and because of its dextrous capability can then place
it into the end cap, at an adjacent point, before returning to repeat
the process. The method can be reversed.
[0124] After the previous Laser cut, the Primary reel of Tyvek
indexes forward on command, to present a new area of uncut web to
the suction cup section of the pick and place robot arm, and the
expended perforated section of the reel of Tyvek is wound onto a
Secondary reel, as scrap. The process then repeats.
[0125] It will be recognised that a bank of suction pads can be
arranged to accommodate a number of discs to be cut either singly
by the computerised Laser beam moving from one location to the next,
or by a number of Laser beams working simultaneously.
[0126] Stage 3A Emplacing the Membrane in the Lid
[0127] The end caps are presented to an adjacent point of access
for the robot arm, in an open, end-up position, delivered to that
point via a vibratory bowl feeder and collation device, which sorts
the components into a continuous stream of right-way-up components
ready to receive the Tyvek disc.
[0128] The disc is pressed into the end cap, and is retained by
an interference fit between the outer edge of the disc and the inner
dimension of the outer wall of the end cap which is raised around
its circumference for that purpose. The end cap together with the
inserted Tyvek membrane is now conveyed to the next stage.
[0129] A second stream of end caps, together with inserted Tyvek
membrane discs is conveyed to Stage 5 to cap the other end of the
capsule body, and so form the finished product. The caps in this
second stream of end caps are inverted on route to enable presentation
to the capsule by the robot arm in the correct attitude. The Tyvek
membrane is retained in place, being an interference fit.
[0130] Stage 3) First Assembly of Plastic Components
[0131] The end cap is now part assembled with the inserted Tyvek
membrane disc, and is in the correct attitude of open end/right
way up.
[0132] Tubular bodies, identical at each end, are delivered in
a continuous stream from a vibratory bowl feeder and collation device,
and they are presented to an adjacent point of access for the dextrous
robot arm, to pick and place.
[0133] Each tubular body is picked up by the robot arm, and is
placed precisely into the open side of the end cap, where it is
pressed into place, held in that position by the snap fit design,
trapping the Tyvek membrane therein firmly between the (bottom)
end cap and the tubular body.
[0134] The part-assembled capsule, with the bottom Tyvek membrane
held firmly in place by the snap-on bottom end cap, is now conveyed
to the next stage.
[0135] Stage 4) Filling the Capsule
[0136] At this stage, capsules are correctly positioned for the
filling process, being in an upright position with the open end
at the top.
[0137] The empty capsules are passed beneath a volumetric portion
filling head, and the correct amount and type of content is discharged
from the filling head into the capsule.
[0138] The filled part-assembled capsule is now conveyed to the
next stage.
[0139] Stage 5) Second Assembly of Plastic Components
[0140] The "other end" caps complete with inserted Tyvek
membrane disc are presented to an adjacent point of access for the
dextrous robot arm, in an inverted ready to pick position, delivered
to that point by conveyor from the stage 2 operation. The Tyvek
is retained by an interference fit.
[0141] The inverted cap end is picked up by the robot arm, and
is placed precisely onto the open top of the filled capsule body,
where it is pressed into place, held in that position by the snap
fit design, trapping the Tyvek membrane therein firmly between the
cap and the tubular body.
[0142] The completely assembled capsule is now prepared for ultrasonic
welding.
[0143] Stage 6) Ultrasonic Welding the Desiccant Stopper Together
[0144] The completely assembled capsule is presented to a position
directly beneath the Actuator. The Actuator is set for distance
of downward travel, and also set for the degree of force to be applied
during the ultrasonic vibration period. It is also set for the length
of time of contact with the work-piece.
[0145] The Converter is set for the degree of required Amplitude
and the length of time of energising the Horn/(sonotrode).
[0146] The welding process is commenced with an electronic command
from the controller; the duration of the entire operation is less
than two seconds.
[0147] It will be understood that more than one capsule can be
welded at a time. Dependent upon the type of ultrasonic vibratory
equipment employed, and the physical size of the components, more
than one weld can be executed on the same work-piece at the same
time by tuning the Converter and the Acoustic Tooling to accommodate
both near field and far field distances of energy transmission.
Success is conditional on component design, size, and the suitability
of the materials being used. |