Joining Polymer Parts

Chapter

Vibration Welding
This is what is said to be the largest
vibration-welded plastic intake manifold in
North America: its for the Ford 5.4-liter
SOHC Triton V8 engine (used for F-Series,
Econoline, Expedition, and Excursion
applications). The manifold was developed
by a team consisting of representatives
from Ford, molder Montaplast North
America, and plastics-supplier DuPont
Automotive. How big? 16.3-kg of Zytel
welding-enhanced PA 66 nylon resin are
used. The welding enhancement is
important in that there is a 4-meter long
vibration weld that joins the bottom and top
halves of the manifold.

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

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

That is, he says that in 1998, 100% of the air intake

manifolds produced in the Americas were made with nylon
66. This is the material that started it all. So the equipment
necessary to make manifolds with this materialmainly
lost-core moldingis 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 6
which, Ferrighetto explains, provides an overall cost
advantage 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 that
by 2004, there may be a 60/40 split between 66 and 6.

Ultrasonic Welding

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

Hot Plate Welding

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

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

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

Snap fit calculator from Engineers Edge

www.engineersedge.com/ snap_fit_tapered.htm

Snap fit Design excerpt from Paul E. Tres book

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

Tres

Tres

Recommended Living Hinge Feature for Polypropylene1

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

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

The COMpliant fishing PLIERS (COMPLIERS) are designed

to conveniently remove fish hooks through a combination of
grasping and disgorging actions. This special compliant
mechanism 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

Compliant Mechanism
research.et.byu.edu/ llhwww/special/parallel.html
http://research.et.byu.edu/llhwww/intro/advantage.html

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