CA2058335C - System and method for remotely heating a polymeric material to a selected temperature - Google Patents

System and method for remotely heating a polymeric material to a selected temperature Download PDF

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Publication number
CA2058335C
CA2058335C CA 2058335 CA2058335A CA2058335C CA 2058335 C CA2058335 C CA 2058335C CA 2058335 CA2058335 CA 2058335 CA 2058335 A CA2058335 A CA 2058335A CA 2058335 C CA2058335 C CA 2058335C
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CA
Canada
Prior art keywords
polymeric
composite
particulate
temperature
ferromagnetic material
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.)
Expired - Lifetime
Application number
CA 2058335
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French (fr)
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CA2058335A1 (en
Inventor
William Guy Clark Jr.
Robert Edward Shannon
Warren Robert Junker
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CBS Corp
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Westinghouse Electric Corp
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Publication date
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Publication of CA2058335A1 publication Critical patent/CA2058335A1/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/88Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1403Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the type of electromagnetic or particle radiation
    • B29C65/1425Microwave radiation
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1429Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface
    • B29C65/1435Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. transmission welding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1477Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation making use of an absorber or impact modifier
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1477Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation making use of an absorber or impact modifier
    • B29C65/148Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation making use of an absorber or impact modifier placed at the interface
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1477Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation making use of an absorber or impact modifier
    • B29C65/1483Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation making use of an absorber or impact modifier coated on the article
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/34Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/36Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction
    • B29C65/3604Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the type of elements heated by induction which remain in the joint
    • B29C65/3608Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the type of elements heated by induction which remain in the joint comprising single particles, e.g. fillers or discontinuous fibre-reinforcements
    • B29C65/3612Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the type of elements heated by induction which remain in the joint comprising single particles, e.g. fillers or discontinuous fibre-reinforcements comprising fillers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/483Reactive adhesives, e.g. chemically curing adhesives
    • B29C65/4835Heat curing adhesives
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4855Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by their physical properties, e.g. being electrically-conductive
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4865Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding containing additives
    • B29C65/487Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding containing additives characterised by their shape, e.g. being fibres or being spherical
    • B29C65/4875Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding containing additives characterised by their shape, e.g. being fibres or being spherical being spherical, e.g. particles or powders
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5007Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like characterised by the structure of said adhesive tape, threads or the like
    • B29C65/5021Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like characterised by the structure of said adhesive tape, threads or the like being multi-layered
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5057Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like positioned between the surfaces to be joined
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/82Testing the joint
    • B29C65/8207Testing the joint by mechanical methods
    • B29C65/8215Tensile tests
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11Joint 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
    • B29C66/112Single lapped joints
    • B29C66/1122Single lap to lap joints, i.e. overlap joints
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11Joint 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
    • B29C66/114Single butt joints
    • B29C66/1142Single butt to butt joints
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/40General 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
    • B29C66/41Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43Joining a relatively small portion of the surface of said articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/80General aspects of machine operations or constructions and parts thereof
    • B29C66/81General 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
    • B29C66/812General 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 composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/8126General 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 composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/81266Optical properties, e.g. transparency, reflectivity
    • B29C66/81267Transparent to electromagnetic radiation, e.g. to visible light
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/80General aspects of machine operations or constructions and parts thereof
    • B29C66/83General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/834General 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
    • B29C66/8341Roller, cylinder or drum types; Band or belt types; Ball types
    • B29C66/83411Roller, cylinder or drum types
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/80General aspects of machine operations or constructions and parts thereof
    • B29C66/83General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/834General 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
    • B29C66/8341Roller, cylinder or drum types; Band or belt types; Ball types
    • B29C66/83411Roller, cylinder or drum types
    • B29C66/83417Roller, cylinder or drum types said rollers, cylinders or drums being hollow
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/90Measuring or controlling the joining process
    • B29C66/91Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91411Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the parts to be joined, e.g. the joining process taking the temperature of the parts to be joined into account
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/90Measuring or controlling the joining process
    • B29C66/91Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9161Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/90Measuring or controlling the joining process
    • B29C66/91Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C67/00Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/24Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 characterised by the choice of material
    • B29C67/247Moulding polymers or prepolymers containing ingredients in a frangible packaging, e.g. microcapsules
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0855Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using microwave
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/82Testing the joint
    • B29C65/8207Testing the joint by mechanical methods
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General 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
    • B29C66/71General 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 composition of the plastics material of the parts to be joined
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General 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
    • B29C66/73General 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
    • B29C66/739General 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
    • B29C66/7392General 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
    • B29C66/73921General 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/90Measuring or controlling the joining process
    • B29C66/95Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94
    • B29C66/959Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 characterised by specific values or ranges of said specific variables
    • B29C66/9592Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 characterised by specific values or ranges of said specific variables in explicit relation to another variable, e.g. X-Y diagrams
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2909/00Use of inorganic materials not provided for in groups B29K2803/00 - B29K2807/00, as mould material
    • B29K2909/08Glass
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0003Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular electrical or magnetic properties, e.g. piezoelectric
    • B29K2995/0008Magnetic or paramagnetic
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/0026Transparent
    • B29K2995/0027Transparent for light outside the visible spectrum

Abstract

Both a system and method are provided for remotely heating a polymeric material to a selected temperature.
The system generally comprises particulate ferro-magnetic material dispersed throughout the polymeric material to form a composite, wherein the particulate material has a Curie temperature that corresponds to the selected heating temperature, and a source of microwave energy for remotely applying a beam of microwave energy to the polymeric composite material.
Preferably, the particulate ferromagnetic material comprises only about 2 percent of the total composite by weight. The polymeric material may be compliant, thermosettable plastic, and the Curie temperature of the particulate ferromagnetic material dispersed therein may advantageously be above the curing temperature of the polymer, such that the beam from the source of microwave energy may be used to remotely join surfaces or construct joints in composite structures.
Alternatively, the polymeric material may be a meltable plastic, and the Curie temperature of the particulate ferromagnetic material may be chosen to be above the temperature of fusion of the polymer to create a polymeric composite which is magnetically separable from other polymers within a solid waste facility, and which may be melted down for recycling purposes. In a variation of this embodiment, a heat actuatable degradation chemical may be dispersed through the polymeric material along with the ferro-magnetic material to create a plastic composite which is selectively degradable by the remote application of microwave energy.

Description

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- 1 - W.E. 56,399 4 Backuround of the Invention -6 This invention generally relates to systems and 7 methods for remotely heating polymeric materials to 8 selected temperatures by the dispersion of particulate 9 ferromagnetic materials throughout the polymers whose Curie temperatures correspond to the selected 11 temperatures of heating. Both the system and the 12 method find particular application in the remote 1:. formation of joints in composite structures, and may be 14 used to form plastic materials which are either recyclable, or reparably heat degradable.
16 Thermosettable plastic materials for forming 17 ~ mechanical joints or other structures are known in the 18 prior art. In their uncured state, such materials may 19 resemble either viscous liquids, putty-like solids, or even flexible, tape-like materials Which may be 21- manipulated into a desired shape, and then heat-cured 22 to form a tough plastic solid that assumes the shape 23 that the uncured polymer was last manipulated into.
24 ~ These materials find particular application with respect to the construction of joints in composite 26 ' structures, such as in the graphite composite frames of 27 w state-of-the-art aircraft.
28 Unfortunately, there are a number of drawbacks 29 associated with the use of such thermo~~ttable polymers to construct aircraft frames and other structures that 31 significantly limits their usefulness. Fir example, at 32 some stages of construction, it is desirable if nod 33 absolutely necessary that the heat used to thermoset 34 the polymer be applied only locally to the specific area of the joint, as the application of such heat to 36 the surrounding components may damage or degrade them.
37 In such instances, the application of heat in the form - 2 - W.E. 56,~~~~'j 1 of infrared radiation must be performed very,carefully, 2 and with appropriate shielding so .as not to damage the 3 surrounding components. Still other difficulties arise 4 with respect to the inspection of the surrounding joints. As joints formed entirely of plastics and 6~ other~composite materials are transparent to,X-rays, it 7 is not possible to inspect the joint for bubbles, 8 cracks, or other quality-degrading discontinuities with 9 the same kind of X-ray equipment used to inspect ~ metallic joints.-.Finally, both of these aforementioned 11 problems.become e~cacerbated.when it is.necessaxy to 12 perform the repair of a joint formed from such 1' ~ thermosettable, polymeric materials since the remote 14 ~ and focused application of the energy necessary to heat-cure the thermosetting plastic used in the repair 16 becomes difficult, if not impossible, as does the 17 ability to remotely inspect the. repaired joint. While 18 ~ these problems migh~~be overcome by the provision of 19 polymeric materials that are remotely heatable td ,20 selected temperatures corresponding to the curing 21._. temperatures of the polymers, thus far no such polymers 22 have been developed in the prior art.
23 Still another set of problems which might be 2Q ~ solved by provision of selectively and ,remotely '25 heatable plastic materials occurs in the area of 26 recyclable and degradable plastic materials.
27 . Recyclable plastics are known in the prior art. Such 28 plastic materials may be used as wrapping or packaging 29 materials for food products and manufactured goods, and 30 then separated from other solid waste materials after 31 being discarded and finally melted back down into a raw 32 plastic material suitable for reuse. However, the lack 33 of a convenient wag to separate such reusable plastics 34 after they are commingled with other unrecyclable 35 polymeric materials and solid wastes has severely 36 limited the usefulness of recyclable plastics. And 3? while degradable plastics are known, these plastics are - 3 - W.E. 56,399 1 likewise not easily separable from other plastic 2 materials and solid waste which they may be commingled 3 with upon disposal. Many known degradable plastics 4 further suffer from the disadvantage of being vulnerable to degradation when such degradation is not 6 desirable. Such problems might be solved by the 7 provision of polymeric materials that, even when 8 commingled with other materials, are separately 9 heatable to a temperature corresponding to their fusion -temperatures so that they might be melted out and 11 separated from other solid wastes.
12 Clearly, there is a need for plastic materials 1' . which are selectively and remotely heatable to a 14 desired temperature, and which are further relatively easy to separate after being commingled with other lfi polymeric materials and. solid wastes.

18 Summary of the Invention 20: Generally speaking, the invention is both a system 21 and method for remotely heating a polymeric material to 22 a selected temperature by means of a directed beam of 23 ,microwave energy. The system of the invention 2~ ~ generally comprises a particulate ferromagnetic material dispersed throughout the polymeric material to 28 form a composite, wherein the particulate, material has 27 a Curie temperature that corresponds to the selected 28 ~ heating temperature, and a source of microwave energy 29 for remotely applying microwaves to the polymeric composite. The particulate ferromagnetic material is 31 preferably composed of particles of a spinel ferrite 32 which comprises between about 0.1 percent and 10 33 . percent by weight of the polymeric composite material.
34 Preferably, the diameter of the particles of ferromagnetic material range between about 10 and 1000 36 Angstroms, and more preferably within a range between 37 ~ about 50 and 150 Angstroms.

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- 4 - w.E. 56,399 1 The system of the invention may assume the form of 2 ~ a variety of different embodiments, each of which has 3 its own unique advantages over the prior art. For 4 example, the polymeric material may be a thermosettable polymer, and the Curie temperature of the particulate 6 ferromagnetic material may be chosen to be above the 7 thermosetting temperature of the polymer, and the 8 source of microwave energy of the system may be used to 9 selectively cure the composite into solid form. Since the surrounding polymeric mater3.als are unaffected by 11 microwave radiation, only the ferrite-containing 12 composite will be heated by the microwave beam. This 1." particular embodiment of the invention finds 14 application as an adhesive. In the method of this embodiment of the system of the invention, uncured 16 polymeric composite in a semi-liquid form may be 17 applied between two surfaces desired to be joined, and 18 a beam of microwave energy may be selectively focused 19 onto the uncured composite to advantageously join the two surfaces. In a related embodiment of the 21 invention, the Curie temperature of the ferromagnetic 22 particles may be chosen so that they are just above the 23 fusion temperature of the polymeric material, and the .2~ ~ polymeric material may be applied between tvao surfaces desired to be joined and then melted to join these 26 surfaces by the focused application of the beam of 27 , microwave energy.
28 Other embodiments of the system and method of the 29 invention may be used to either recycle or to degrade polymeric materials into harmless composts. For 31 example, the Curie temperature of the ferromagnetic 32 particles may be chosen to be higher than the fusion 33 temperature of the polymeric material, and in the 34 method of this particular embodiment of the invention, the composite polymeric material, if commingled with 36 other polymeric materials in a solid waste facility, 37 may be first magnetically separated from the other r~t~~a' - 5 - W.~. 56,399 1 polymeric materials, arid then melted for reuse by the 2 selective application of a beam of microwave energy to 3 the separated composite. Alternatively, the polymeric 4 composite may be separated from the other polymeric materials which it is commingled with by the 6 application of a sufficient amount of microwave energy 7 tb completely melt the composite so that it runs off 8 from the other commingled materials.
9 In still another embodiment of the system of the invention, a heat actuatable degradation chemical is 11 dispersed throughout the polymeric material along with 12 the ferromagnetic material, and the Curie point of the 1 ferromagnetic material is chosen to be above the 14 actuation temperature of the degradation chemical. In 1S the associated method of the invention, the polymer 16 composite may first be magnetically separated from 17 other polymeric materials with which it is commingled 18 with, and then reduced to a harmless compost by the 19 selective actuation of the degradation chemical by microwave energy.
21. ~ In all the aforementioned embodiments, the 22 selection of a ferromagnetic material having a Curie 23 temperature which interacts with some property of the ~2 surrounding polymeric material to achieve a useful result, in combination with a directable beam of 26 microwave energy that is capable of remotely heating 27' . the resulting composite to the Curie temperature of the 28 ferromagnetic particles, advantageously results in an 29 invention that may be used to remotely join or bond together different structural components of a composite 31' structure, or to create a system for separating, 32 recycling, or degrading polymeric materials in a solid 33 waste facility.

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1 Brief Description of the Several Fit,~ures 3 Figure lA illustrates the polymeric composite and 4 source of microwave radiation which generally form the system of the invention;
6 Figure 1B and~lC represent the particulate ferro-7 magnetic material and the polymeric material which, 8 when mixed together, form the polymeric composite of 9 the system of the invention;
Figure 2A illustrates how one embodiment of the li ~ system of the invention may be used to bind together 12 opposing surfaces of a pair of different .structural 1 components wherein the polymeric composite used 14 includes a heat curable thermoplastic;
IS Figure 2B illustrates how the heat curable 16 thermoplastic used in the polymeric composite of the 17 invention might be remotely heat cured by the 18 application of a beam of microwave energy;
19 Figure 2C illustrates how the resulting, heat-~ cured thermoplastic-containing composite material can 21-- form a permanent and secure bond between the opposing 22 surfaces of the two structural components;
23 Figure 3A discloses how the system of the '2 invention may be used to find together the edges of a pair of microwave-transparent sheet materials,, wherein 26 the polymer composite used is a flexible strip of 27 ~ uncured thermoplastic material having particulate 28 ferromagnetic material incorporated therein;
29 Figure 3B illustrates a variation of the embodiment of the invention illustrated in Figure 3A~, 31 ' wherein the polymer composite material takes the form 32 of a putty-like thermoplastic having particulate ferro-33- magnetic material incorporated therein;
34, Figure 3C is still another variation of the system 35v of the invention illustrated in Figure 3A, wherein the 36 edges of the m:Lcrowave-transparent sheet material are -37 formed from a fusyble plastic material, and have - 7 - W.E. 56,399 1 particulate ferromagnetic material incorporated therein 2 such that these edges may fuse together and form a bond 3 when exposed to a beam of microwave energy;
4 Figure 3D is a graph illustrating how the lap shear strength of an epoxy bonding composite is 6 affected by different concentrations of ferrite particles;

8 Figure 4 illustrates a-heat degradable compositeof 9 the system of the invention, 'vherein the polymeric -10 composite'has particles of a heat actuated degradation 11 chemical distributed through its polymeric matrix along 12 with particles of ferromagnetic material;

1 . Figure 5 is a variation of the heat degradable 14 composite illustrated in Figure 4, wherein the ferromagnetic particles are encapsulated within the 16 particles of the heat-actuated degradation chemical, .17 which is in turn uni-formly distributed through the 18 polymer matrix of~the Composite;

I9~ Figure 6 illustrates still another heat degradable .

composite of the invention, wherein a degradation ~

21. chemical is encapsulated within a heat-fusible plastic 22 material, along with one or more particles of .23 ferromagnetic material;

~2 ' Figure 7 is a flowchart of a plastic recycling method which is within the scope o the instant 26 invention, and 27 Figure 8 is a flowchart of a plastic degradation 28 method which is also within the scope of the instant invention.

3 U' _ 31 Detailed Description of the Preferred Embodiment ;33 . With reference now to Figures lA, 1B, and 1C, 34. system 1 of the invention generally comprises a polymeric composite 3 formed from a polymeric material 36 5 mixed with am particulate ferromagnetic material 7, 37 and a source 9 of microwave radiation. In the - 8 - W.E. 56,399 i e.J
1 preferred embodiment, the Curie temperature of the 2 particulate ferromagnetic material 7 is chosen so that 3 it has some desired or useful effect upon the matrix of 4 polymeric material 5 within which it is embedded. For example, if the polymeric material 5 is an uncured 6 thermoplastic, the Curie temperature of the 7 ferromagnetic material 7 may be chosen so that it is 8 above the curing temperature of the material 5.
9 Similarly, if one wishes to melt or fuse the polymeric material 5 in the ultimate application of the composite 11 3,_the Curie temperature of the particulate 12 ferromagnetic material 7 is chosen to be above the 1' melting point of the ferromagnetic material 5. In the 14 preferred embodiment, the particulate ferromagnetic material 7 used are fine particles of spinet ferrites 16 whose diameters range between 50 to 500 Angstroms and 17 whose Curie temperatures range between 50°C, to 700°C.
18 The particulate ferromagnetic material 7 may comprise 19 anywhere between 0.1 to 10 percent by weight of the resulting polymeric composite 3, and more preferably 21 comprises between ~l and.2 weight percent of the 22 resulting composite 3. Ferrites are generally the 23 particles of choice for all of the various embodiments 2 ~ of the invention since such particles are characterized by a Curie temperature limit. However, any particulate 26 matter having a Curie temperature that determines the 27 . maximum temperature that the particles may be heated to 28 by microwave radiation is within the scope of the 29 invention. By contrast, while many types of metallic particles may be heated by microwave radiation, many 31 such particles are not characterized by a Curie 32 temperature. Hence they can heat up without limit when 33 exposed to microwave radiation. The applicants have 34 found that an excellent source of fine particles of spinet ferrites is present in a waste product of the 36 wood processing industry that is designated as 37 ferromagnetic iron lignosuafonate, and which comprises I .s s.a Y',.
- 9 - W.E. 56,399 ~i,~~~z~.v,~~j 1 such fine particulate ferrites (50-0150 Angstroms) 2 colloidally suspended in an aqueous solution. Such 3 lignosulfonate may be obtained from, fox example, the 4 Georgia Pacific Corporation located in Bellingham, Washington. While the source of microwave radiation 6 9 may emit microwaves having a frequency of from 7 anywhere between 400 MHz and 3,000 MHz, microwaves in 8 the upper section of the frequency range are preferred 9 due to the fact that they are easier to direct into a relatively narrow .beam. As will be more fully 11 ~ appreciated later, the ability to collimate in focus 12 such microwave energy is a particularly useful. feature 1' ~ in the context of this invention, as it allows the 14 _ system operators to deliberately and remotely apply microwave energy to a~ particular location where it is 16 desire to heat the composite 3.

'1? Figures 2A, 2B and 2C illustrate one embodiment of 18 the system 1 of the invention which may advantageously 19 be used to bind together opposing surfaces l5a,b of a pair of structural components l7a,b. For this purpose, 21 the polymeric material 5 used in the comgosite 3 is a 22 liquid or putty-like polymer that hardens when exposed 23 to heat. Examples of such thermosetting polymers .2 ~ include epoxies, polyesters, polyurethanes, polybutadienes, cyanate esters, bismaleimides, 26 polyimides, phenolics, alkyds, amino resins, and even .27 silicones. Any such thermosetting plastic material 28 that permanently hardens or "sets" when heated above a 29 selected temperature is included within the scope of this invention. In the application of the invention 31 illustrated in Figures 2A, 2B and 2C, a quantity of 32 particulate ferromagnetic materials 7 is intermixed 33 with the thermosetting plastic that forms the polymeric 34 material 5 in order to form a putty-like polymer composite 3. This composite 3 is applied between the 36 surfaces l5a,b to be bonded together. Then, as is 3? illustrated in Figure 2B, the polymeric composite 3 may ~!~ ''~ ~: %~ P"
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1 be exposed to a collimated beam 13 of microwaves 2 radiated from the reflector 11 of the source 9 of 3 microwave radiation. Such a beam 13 may be easily and 4 conveniently applied even when the polymer composite 3 is disposed behind a panel 17c, so long as the panel 6 17c is transparent to microwave radiation. After the 7 absorption of the beam 13 of microwave energy ;by the 8 particulate ferromagnetic material 7 within the 9 composite 3 causes the polymer composite 3 to heat up' to the Curie temperature of the ferromagnetic material 11 ? and to permanently thermoset the composite 3, a 12 permanent joint is created between two structural 1' components l7a,b, as is illustrated in~ Figure 2. The 14 directability of the beam 13 of microwaves from the microwave source 9, coupled with the fact that these 16 microwaves easily penetrate through most non-metallic 17 components., confers great utility of this particular 18 embodiment of the system 1 in creating joints or in 19 ' repairing joints in composite structures (such as the new graphite frames currently being manufactured for 21. some airplanes) as it allows such joints to be created 22 without the application of unwanted heat to large 23 portions of the composite structure being built, and ~2 ~ further allows such heat to be selectively and remotely applied to potions of the resulting structure which 26 are either physically inaccessible to the microwave 27 source 9, or covered by microwave- transparent 28 components such as panel 17c.
29 Figures 3A, 3B and 3C illustrate still another '3p embodiment of the invention which may be advantageously 31 used to join together the edges of upper and lower 32 sheet 18,19 of a material that is substantially 33 transparent to microwave radiation. In this 34 embodiment, the polymeric composite 3 assumes the form of a pliant tape or strip 20 that is formed from an 36 uncured, thermosetting plastic that has been mixed with 3T particulate~fe~romagnetic material 7 in the proportions qy;"'~yc~r;
- 11 - w . E . 5 6 , 3 9 9 ~';i <s a ~I ~ :.j 1 previously described. This tape or strip form 20 of 2 the uncured polymeric material 5 advantageously 3 includes adhesive layers 2la,b on either or both its 4 upper and lower sides so that it may conveniently be affixed into a proper position between the overlapping 6 sheets 18,19 prior to the bonding operation. After the 7 tape or strip 20 has been affixed by the adhesive 8 layers 2la,b in the position illustrated in Figure 3A, 9 a roller 23 preferably formed from a microwave-transparent material and supported by side. bearings 11 24a,b is applied over the overlapping portions of the 12 upper and lower sheets 18,19 in order to join the same.
1 The roller 23 includes a microwave source 25 that 14 directs a beam of microwave energy which is sufficient in magnitude to bring the particulate ferromagnetic 16 material 7 up to its Curie temperature (which is chosen 17 to be above the thermosetting temperature of the 18 polymeric material 5 used in the composite 3), which in 19 turn causes the composite 3 to harden and to join the ~ upper and lower sheets 18,19 21 Figure 3B illustrates a variation of the 22 embodiment of the invention illustrated in Figure 3A, .23 the only difference being that the polymeric composite v2 3 is formed from a putty-like thermosetting plastic that has been impregnated with a particulate 26 ~ ferromagnetic material 7, instead of a thermosetting 27 . material 5 which, in its uncured state, forms a pliant 28 tape or strip 20. 'In the variation of the'indention 29 illustrated in Figure 3B, it is envisioned that the uncured composite 3 might be applied by means of a 31 caulking gun in much the same way that caulking 32 isapplied.around the windows and rain gutters of modern 33 homes and buildings.
34 Figure 3C illustrates still another variation of the invention which may advantageously be used in 36 conjunction with the roller device illustrated in 3? Figure 3A to form a joint between the overlapping edges - 12 - ~~.E.. 56,399 1 of an upper and l..ower 18, 19 sheet of microwave 2 transparent sheet material. However, in this 3 particular variation of. the invention,~the sheets 18,19 4 are formed from fusible thermoplastics which, when melted, are capable of hardening into a permanent 6 joint. In this particular variation of the invention, 7 only an edge portion 27 of each of the sheets 18,19 is 8 impregnated with a particulate ferromagnetic material 7 9 whose Curie temperature is higher than the temperature of fusion of the thermoplastic material from which the 11 ~ upper and lower sheets 18,19 are formed. The edge 12 portions 27 of the .sheets 18,19 are overlapped as is 1" illustrated in Figure 3C, and the roller device 23 14 illustrated in Figure 3A is used to fuse a joint between the twa sheets 18,19. In this variation of the 16 ~ invention, it should be noted that the provision of the 17 particulate ferromagnetic material 7 in only the edge 18 portions 27 obviates the need for the operator to 19 carefully direct the beam of microwaves from the ~ microwave source 25, as the portions of the sheets 21_ 18,19 which are devoid of the particulate ferromagnetic 22 material 7 will not be heated by the accidental 23 application of such microwaves.
.2~ , Figure 3D illustrates how the lap shear strength ' of an epoxy-based polymeric composite is affected by 2fi different concentrations of ferrite particles; The 27 data on this graph surprisingly illustrates that the 28 lap strength of an epoxy-based composite can actually 29 increase with a ferrite content of up to 0.66 weight percent. Such a weight percentage of ferrite particles -31 is ample to effect the heat-curing of the composite, 32 and to allow for an eddy current probe inspection of 33 ~ the cured epoxy bond:
34 Both the system l and the method of the invention may also be advantageously used to create recyclable 36 plastic composites. Such a recyclable composite may be 37 formed from a thermoplastic such as a polyolefin, - 13 - W.E. 56,399 1 polyester, liquid crystal polymer, polyoxy methylene, 2 acrylic, fluoropolymer, or polyamide) into which 3 ferromagnetic particles having a Curie temperature 4 higher than the fusion point of the surrounding thermoplastic material are admixed. An example of such 6 a recyclable composite material might be a mixture of ? polyvinyl chloride, and about 2 percent by weight 8 spinal ferrite particles whose Curie temperature is 9 equal to or greater than the fusion point of the surrounding polyvinyl chloride matrix.. As will be 11 described in more detail hereinafter, the presence of 12 the particulate ferromagnetic material in the polyvinyl 1" chloride allows the resulting "tagged" composite 14 material to be magnetically separated from other - plastics in which it may be commingled with '(say for 16 example, at a solid waste facility), and then melted 1?, down for reuse by the application of a beam of 18 microwave energy.
19 Figure 4 illustrates an embodiment of the system .20 of the invention which may be advantageously used to 21 create a selectively degradable plastic composite 30.
22 Such a composite 30 may be formed from a polymeric 23 material 5 into which both a particulate ferromagnetic ,2 ~ material 7 and particles of a heat actuated degradation chemica1~32 have been admixed. The degradation 26 chemical 32 is chosen so that it structurally degrades 2? . and destroys the surrounding matrix polymeric material 28 5 when it is actuated, and the Curie temperature of the 29 particulate ferromagnetic material ? is chosen to be equal to or greater than the triggering temperature of 31 the heat actuated degradation chemical 32. Such a heat 32 degradable composite 30 may be made from common 33 polyvinyl chloride, into which between 1 and 2 weight 34 percent of spinal ferxite particles had been uniformly dispersed, along with small droplets 32 of an organic 36 peroxide such as benzoyl peroxide. In the preferred 3? embodiment, the benzoyl peroxide should constitute ' ;,. ~ ~ ~..~ Q..
- 14 - W.E. 55,399 1 between 1 and 5 weight percent of the polyvinyl 2 chloride material 5, and the Curie temperature of the 3 spinel ferrite admixed into the polyvinyl chloride 5 4 should be about 100°C. When such a composite 30 is exposed to a dose of microwave energy which creates 6 localized temperatures within the structure of the 7 composite approaching the Curie temperature of the 8 spinel ferrites 7, the benzoyl peroxide droplets 32 9 will release elemental oxygen, which will oxidize and ~ ' break the polymeric chains of polyvinyl chloride at 11 numerous situses within the composite 30. In a short 12 time after exposure to such microwave radiation, such a 1" composite 30 will, upon the application of small 14 amounts of mechanical pressure, crumble into numerous small. particles suitable for use as a compost.
16 Figure 5 illustrates an alternate embodiment of a 17 heat degradable composite 30 formed in accordance with 18 the system and method of the invention. Tn this 19 embodiment, the benzoyl peroxide 32 and particulate ferromagnetic material 7 are thoroughly admixed 21- together before being introduced into the matrix of 22 polyvinyl chloride. Hence, when the mixture of benzoyl 23 peroxide and particulate ferromagnetic material 7 is '2 ~ unizormly dispersed throughout the polyvinyl chloride 25, 5, almost all of the droplets of benzoyl peroxide 26 contains within it one or more particles of spinel 27', ferrite. This particular embodiment of the method and 28 system of the invention has the advantage of applying 29 the heat generated by the particles of spinet ferrite directly on the interface between the droplets of 31 benzoyl peroxide 32, and the surrounding matrix of 32 polyvinyl chloride 5: Hence, less microwave energy is 33 required to trigger the degradation process in the 34 composite 30 illustrated in Figure 5.
Figure 6 illustrates still another embodiment of a 36 heat degradable composite 30, wherein small droplets of 3T benzoyl peroxide 32 and particulate ferromagnetic - 15 - W.E. 56,399 ~'t~~s'~Jc~:'ia.~
1 materials 7 are encapsulated within a thin skin 33 of a 2 plastic material that is relatively 'immune to 3 degradation from benzoyl peroxide, such as 4 polytetrafluoroethylene. Here, the Curie point of the spinel ferrites captures within the thin encapsulating 6 skin 33 of inert plastic is chosen to be above the 7 boiling point of benzoyl peroxide, which is 8 approximately 105°C., so that when the composite 30 9 ~ shown in Figure 6 is exposed to microwave radiation, the benzoyl peroxide partially vaporizes and bursts the 11 thin skin 33 of polytetrafluoroethylene containing it.
12 Once this skin 33 is burst, the oxygen released from 1' the benzoyl peroxide proceeds to destroy the integrity 14 of the surrounding PVC in the same fashion as previously described. While the degradable composite 16 30 illustrated in Figure 6 is more difficult to 17 manufacture and requires more microwave energy to 18 ~ degrade, the resulting composite material .is also more 19 stable under a broader range of conditions (such as exposure to intense sun light~or to incidental heat).
-21 With reference now to Figure 7, the invention also 22 encompasses a plastic recycling method 35 that utilizes 23 a polymeric composite 3 formed from a thermoplastic polymer material 5 into which particulate ferromagnetic material has been admixed whose Curie temperature is 26 higher than the fusion temperature of the polymeric 27_ , material 5.
28 In the initial steps of this recycling method 35, 29 a thermbplastic polymer (such. as the aforementioned polyvinyl chloride) is mixed with between 0.5 and 10 31 percent by weight particles of spinet ferrite to form a 32 tagged polymer composite as is,indicated in step 37.
33 At this juncture in the method, the specific microwave 34 absorptive.characteristics of the ferrite particles intermixed within the polymer are noted, so that the 36 ~ source of the particular tagged polymer composite might 37 be identified at a later time. After the composite has - 16 - W.E. 56,399 ~,u~~~f~~?:::~.3 1 been formed and the specific characteristics of the .2 ferrite particles within have been recorded for such 3 identification purposes, the composite is then applied 4 to a practical use, such as packaging as is indicated in step 39. Ultimately, as is indicated in step 41, 6 this packaging is discarded as waste which is 7 commingled with other solid waste as is indicated in 8 step 43. The commingled solid waste is then ultimately 9 delivered to a solid waste processing facility (not shown). This method of .the invention requires the 11 facility to have a magnetic sorting device comprising a 12 bank of magnets (not shown) which are capable of 1' generating localized magnetic fields which are intense 14 enough to sort the tagged polymer composite away from the other polymers in the commingled solid waste which 16 do not contain any ferrite particles, as is indicated 17 ~ in method step 45. The non-magnetic polymeric 18 materials are then removed from the tagged polymer 19 _ composite and then either dumped, or incinerated and ~ then dumped at a designated site at the solid waste 21 facility as is indicated by method steps 47-50.
22 By contrast, the separated, tagged polymer 23 composite is then conveyed to a bank of microwave 2 . ~ radiators as indicated by method steps 51 and 53, and then exposed to a sufficient amount of microwave energy 26 to cause the ferrite particles in the composite to heat 27 ; it to a temperature of over the fusion point of the 28 polymer forming the composite matrix. The melted 29 composite is then recovered for reuse, as is indicated by method steps 53-57.
31 If tagged polymer composites having higher and 32 lower melting points are commingled along with the 33 solid waste in step 53, and are then sorted out from 34 the non-magnetic waste consistent with method step 45, the composites.exposed to the beams of microwave in 36 method step 53 will have different melting points. In 37 such a situation, sufficient microwave heating is T
- 17 - W.E. 56,399 ~~~G'~~'~'-~
1 applied to first completely melt the lower temperature 2 melting polymer so that this polymer. may be collected 3 for reuse (as is indicated in method steps 55 and 57).
4 Subsequently, sufficient microwave energy is applied to the composite having the higher melting point so that 6 this composite may be melted for reuse, as is indicated 7 by method steps 59 and 61. Because different polymers 8 are usually characterized by differing melting points, 9 and because spinet ferrites can tae selected so that the Curie points associated with these ferrites are equal 11 to or greater than the melting points of their host 12 polymer materials, microwave heating step 52 may be 1' used to effectively "distill" various melting polymer 14 composites from one another by incrementally scaling up the amount of power radiated by the bank of microwave 16 radiators located in the solid waste facility so that 17 one type of polymeric composite is completely melted 18 away and collected for reuse before the next type of 19 polymeric composite is then melted.
~ Figure 8 illustrates a plastic degradation method 21:. 65 that is within the scope of the instant invention.
22 In this method, a polymer such as polyvinyl chloride is 23 mixed with not only ferrite particles 7, but one of the 2r ~ previously described heat actuated degradation chemicals 32 to form a tagged polymer composite as is 26 shown in step 37. As was the case with the plastic 27 . recycling method 35, the specific characteristics of .28 the spinet ferrites incorporated within the polymer are 29 recorded at this juncture so that the identity of the source of the composite might be known. The resulting 31 heat degradable composite is used, discarded and sorted 32 as is indicated in method steps 39 through, 51 in the 33 same fashion as the recyclable plastics discussed with 34 reference to the recycling method 35. Finally, the degradable composite 30 is e:k~~.~~'~~i t.~a microwave 36 radiation from the bank of microwave radiators present 37 in the solid waste facility as is indicated in method 18 - W.E. 56,399 '~ , h:>~w:~;~.
~~~C.~C~c~~
C
1 step 69 in order to trigger the degradation chemical 2 impregnated within the composite. This in turn 3 destroys the structural integrity of the composite 4 causing it to crumble into a particulate mass which in turn is buried as a compost in method step 71.

14 .

31 , .
36 .

Claims (22)

1. A system for heating a polymeric material to a selected temperature, comprising a particulate ferromagnetic material dispersed throughout said polymeric material to form a composite, wherein said particulate material has a Curie temperature that corresponds to said selected heating temperature, and a source of microwave energy for remotely directing microwaves, to said polymeric composite material to heat at least a portion of said polymeric material throughout its volume to approximately the Curie temperature of the ferromagnetic material, and a heat actuated degradation chemical dispersed throughout said polymeric material, wherein the Curie temperature of the particulate ferromagnetic material is above the temperature required to actuate said degradation chemical such that said composite degrades when exposed to microwave energy.
2. A system as defined in claim 1, wherein said particulate ferromagnetic material comprises between about 0.1 % and 10% by weight of the polymeric composite material.
3. A system as defined in claim 2, wherein said particulate ferromagnetic material comprises between about 1 % and 5% by weight of the polymeric composite material.
4. A system as defined in claim 1, wherein said ferromagnetic material is a ferrite compound.
5. A system as defined in claim 4, wherein said ferromagnetic material is a spinet ferrite.
6. A system as defined in claim 1, wherein the diameter of the particles of ferromagnetic material range between 10 and 1000 Angstroms.
7. A system as defined in claim 1, wherein the Curie temperature of said particulate ferromagnetic material is between about 50°C to 700°C.
8. A system as defined in claim 1, wherein said source of microwave energy radiates microwaves having a frequency of between about 400 MHz and 3,000 MHz.
9. A system as defined in claim 1, further comprising a means for directing said microwave energy to a selected portion of said polymeric composite.
10. A system as defined in claim 9, wherein said directing means includes a microwave reflector.
11. A system as defined in claim 1, wherein said particulate ferromagnetic material is distributed within particles of said degradation chemical, and said particles of said degradation chemical is in turn dispersed throughout a matrix of said polymeric material.
12. A system as defined in claim 11, wherein said polymeric material is polyvinyl chloride, and said degradation chemical is benzoyl peroxide, and said Curie temperature of said ferromagnetic particles is 105°C.
13. A system as defined in claim 1, wherein said heat actuated degradation chemical dispersed throughout said polymeric material, is encapsulated in microspheres of a material inert to the degradation action of said chemical, and wherein the Curie temperature of said particulate ferromagnetic material is above the temperature required to cause the walls of said microspheres to open.
14. A system as defined in claim 13, wherein said polymeric material is polyvinyl chloride, and said degradation chemical is benzoyl peroxide, and said Curie temperature of said ferromagnetic particles is 105°C.
15. A system as defined in claim 14, wherein said microspheres are formed from polytetrafluoroethylene which burst when said benzoyl peroxide vaporizes at 105°C to expose said polyvinyl chloride to oxygen released by the benzoyl peroxide.
16. A system as defined in claim 1, wherein said polymeric material is polyvinyl chloride, and said degradation chemical is an organic peroxide.
17. A system as defined in claim 16, wherein said organic peroxide is benzoyl peroxide.
18. A method for heating a polymeric material to a selected temperature by the application of microwave energy thereto, comprising the steps of:
(a) selecting a temperature to which to heat the polymeric material;
(b) selecting a particulate ferromagnetic material whose Curie temperature corresponds to said selected temperature;
(c) dispersing said particulate ferromagnetic material throughout a matrix of said polymeric material to form a polymeric composite:
(d) dispersing a heat actuated degradation chemical throughout said polymeric composite, wherein the Curie temperature of the particulate ferromagnetic material is above the temperature required to actuate said degradation chemical, and (e) remotely directing microwave energy to said polymeric composite to heat at least a portion of said polymeric material throughout its volume to approximately the Curie temperature of the ferromagnetic material.
19. A method as defined in claim 18, further including the step of encoding the polymeric composite by identifying and recording distinctive electromagnetic characteristics of the ferromagnetic particulate material distributed through the polymeric material when forming the composite.
20. A method for heating a polymeric material to a selected temperature by the application of microwave energy thereto, comprising the steps of:
(a) selecting a particulate ferromagnetic material whose Curie temperature corresponds to said selected temperature;
(b) dispersing said particulate ferromagnetic material throughout a matrix of said polymeric material to form a polymeric composite;
(c) comingling said polymeric composite with other polymeric materials;
(d) electromagnetically locating said polymeric composite within said comingled polymeric material;
(e) magnetically separating said polymeric composite from said comingled materials, and (f) applying microwave energy to said polymeric composite.
21. A method as defined in claim 20, wherein said polymeric composite has been commingled with other polymeric composites that contain particulate ferromagnetic material having different Curie temperatures, each Curie temperature being lower than the melting point of the polymeric material that it is distributed within.
22. A method as defined in claim 21, further including the step of applying sufficient microwave energy to said commingled polymeric composites so that all of said composites except the composite containing the ferromagnetic material having the highest Curie point are heated to their respective Curie temperatures, and then magnetically separating said composite having the ferromagnetic material with the highest Curie point.
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US5391595A (en) 1995-02-21
JPH0542548A (en) 1993-02-23
DE69124792D1 (en) 1997-04-03
US5317045A (en) 1994-05-31
US5272216A (en) 1993-12-21
CA2058335A1 (en) 1992-06-29
EP0498998B1 (en) 1997-02-26
EP0498998A2 (en) 1992-08-19
DE69124792T2 (en) 1997-10-09
EP0498998A3 (en) 1993-10-20

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