8/13/2019 02. Plastic Joining

1/18

Joining Polymer PartsChapter

8/13/2019 02. Plastic Joining

2/18

This is what is said to be the largestvibration-welded plastic intake manifold inNorth America: its for the Ford 5.4-literSOHC Triton V8 engine (used for F-Series,Econoline, Expedition, and Excursionapplications). The manifold was developed

by a team consisting of representativesfrom Ford, molder Montaplast North

America, and plastics-supplier DuPont Automotive. How big? 16.3-kg of Zytelwelding-enhanced PA 66 nylon resin areused. The welding enhancement is

important in that there is a 4-meter long vibration weld that joins the bottom and tophalves of the manifold.

Vibration Welding

http://www.autofieldguide.com/articles/050003.html

http://www.ford.com/http://www.autofieldguide.com/articles/050003.htmlhttp://www.autofieldguide.com/articles/050003.htmlhttp://www.ford.com/

8/13/2019 02. Plastic Joining

3/18

http://www.automotive.dupont.com/en/pdfFiles/nylonUnderthehood.pdf

http://www.automotive.dupont.com/en/pdfFiles/nylonUnderthehood.pdfhttp://www.automotive.dupont.com/en/pdfFiles/nylonUnderthehood.pdf

8/13/2019 02. Plastic Joining

4/18

That is, he says that in 1998, 100% of the air intakemanifolds produced in the Americas were made with nylon66. This is the material that started it all. So the equipmentnecessary to make manifolds with this material mainlylost-core molding is in place. There is installed capacity.But in the not-too-distant future, as there are manifold

redesigns, there is, that data describe, a change to nylon 6which, Ferrighetto explains, provides an overall costadvantage in that there is a lower capital equipment cost(the approach here is to make separate parts that are

joined through vibration welding ), a reduced cycle time,

and a slightly lower material cost. The numbers indicate thatby 2004, there may be a 60/40 split between 66 and 6.

8/13/2019 02. Plastic Joining

5/18

www.twi.co.uk/professional/ getFile/jk61.html

Ultrasonic Welding

http://www.twi.co.uk/professional/getFile/jk61.htmlhttp://www.twi.co.uk/professional/getFile/jk61.html

8/13/2019 02. Plastic Joining

6/18

8/13/2019 02. Plastic Joining

7/18

8/13/2019 02. Plastic Joining

8/18

8/13/2019 02. Plastic Joining

9/18

www.twi.co.uk/j32k/ getfile/pjkhotplate.html

Hot Plate Welding

http://www.twi.co.uk/j32k/getfile/pjkhotplate.htmlhttp://www.twi.co.uk/j32k/getfile/pjkhotplate.html

8/13/2019 02. Plastic Joining

10/18

http://www.dow.com/styron/design/guide/bonding.htm

http://www.dow.com/styron/design/guide/bonding.htmhttp://www.dow.com/styron/design/guide/bonding.htm

8/13/2019 02. Plastic Joining

11/18

http://www.dow.com/styron/design/guide/fits.htm

http://www.dow.com/styron/design/guide/fits.htmhttp://www.dow.com/styron/design/guide/fits.htm

8/13/2019 02. Plastic Joining

12/18

http://engr.bd.psu.edu/pkoch/plasticdesign/snap_design.htm

www.engineersedge.com/ snap_fit_tapered.htm

Snap fit calculator from Engineers Edge

Snap fit Design excerpt from Paul E. Tres book

http://engr.bd.psu.edu/pkoch/plasticdesign/snap_design.htmhttp://www.engineersedge.com/snap_fit_tapered.htmhttp://www.engineersedge.com/snap_fit_tapered.htmhttp://engr.bd.psu.edu/pkoch/plasticdesign/snap_design.htm

8/13/2019 02. Plastic Joining

13/18

Tres

8/13/2019 02. Plastic Joining

14/18

Tres

8/13/2019 02. Plastic Joining

15/18

Recommended Living Hinge Feature for Polypropylene1

http://www.dow.com/polyolefins/about/pptechctr/design/fig_tab/livhinge.htm

http://www.dow.com/polyolefins/about/pptechctr/design/fig_tab/livhinge.htmhttp://www.dow.com/polyolefins/about/pptechctr/design/fig_tab/livhinge.htm

8/13/2019 02. Plastic Joining

16/18

www.rtpcompany.com/ info/molding/design/hinge.htm

http://www.rtpcompany.com/info/molding/design/hinge.htmhttp://www.rtpcompany.com/info/molding/design/hinge.htm

8/13/2019 02. Plastic Joining

17/18

The COMpliant fishing PLIERS (COMPLIERS) are designedto conveniently remove fish hooks through a combination ofgrasping and disgorging actions. This special compliantmechanism design allows easy and safe removal of hooks.Compliers, a one-piece design, are molded from an

advanced engineering polymer.

www.tackleman.co.nz/ products.html

http://www.tackleman.co.nz/products.htmlhttp://www.tackleman.co.nz/products.html

8/13/2019 02. Plastic Joining

18/18

http://research.et.byu.edu/llhwww/intro/advantage.html

Compliant Mechanism

http://research.et.byu.edu/llhwww/current_research/bistable_mech/bistable_page.html

Bistable Mechanism

research.et.byu.edu/ llhwww/special/parallel.html

http://research.et.byu.edu/llhwww/intro/advantage.htmlhttp://research.et.byu.edu/llhwww/current_research/bistable_mech/bistable_page.htmlhttp://research.et.byu.edu/llhwww/special/parallel.htmlhttp://research.et.byu.edu/llhwww/special/parallel.htmlhttp://research.et.byu.edu/llhwww/current_research/bistable_mech/bistable_page.htmlhttp://research.et.byu.edu/llhwww/intro/advantage.html