JOINING SHEETS TO FORM A BELT
A method for joining a first sheet ( 10 ) to a second sheet ( 11 ) includes providing a first rigid plate ( 6 ); providing a gas absorbing layer on the first rigid plate; positioning the first sheet, the first sheet has at least a first layer ( 52 ) and a second layer ( 54 ), on the gas absorbing layer ( 8 ); positioning the second sheet, wherein the second sheet has at least a first layer and a second layer, on the gas absorbing layer; wherein an edge of the of the first sheet abuts an edge of the second sheet; placing a second rigid plate on top of the first and second sheet; wherein the second rigid plate is transparent; applying pressure to the first sheet edge and second sheet edge; and laser welding the edge of the first sheet to the edge of the second sheet with a first laser through the second rigid plate.
1 . A method for joining a first sheet to a second sheet comprising:
providing a first rigid plate;
providing a thermal conductive layer consisting of a material selected from polyethylene terephthalate (PET), polyimide, or polycarbonate on the first rigid plate;
positioning the first sheet, wherein the first sheet has at least a first layer and a second layer, on the thermal conductive layer;
positioning the second sheet, wherein the second sheet has at least a first layer and a second layer, on the thermal conductive layer;
wherein an edge of the first sheet abuts an edge of the second sheet;
placing a second rigid plate on top of the first and second sheet;
wherein the second rigid plate is transparent;
applying pressure to the first sheet edge and second sheet edge; and
laser welding the edge of the first sheet to the edge of the second sheet with a first laser through the second rigid plate.
2 . The method of claim 1 wherein the first and second rigid plates are glass.
3 . The method of claim 2 wherein a second laser welds the edge of the first sheet to the edge of the second sheet through the first rigid plate.
4 . The method of claim 1 wherein the first and second rigid plates are thermal insulators.
5 . The method of claim 1 wherein the first edge and the second edge are tapered at an angle.
6 . The method of claim 1 wherein the first laser comprises a laser connected to a plurality of radiation conducting fibers.
7 . The method of claim 6 further comprising:
operating a first laser in the plurality at a first power at full power to preheat the edge; and
operating a second laser in the plurality at a second power less than the first power.
8 . The method of claim 6 further comprising:
operating a first laser in the plurality at a first power less than full power to preheat the edge; and
operating a second laser in the plurality at a second power greater than the first power.
9 . The method of claim 1 wherein the first laser is a laser diode array.
10 . The method of claim 1 wherein the first layer of the first and second sheet is selected from a group consisting of thermoplastics including polycarbonate, polyimide, polyamide, PET, PEN, PETG, loaded with a laser energy absorbent materials such as carbon or an infrared absorbing dye or pigment.
11 . The method of claim 1 wherein the second layer of the first and second sheet is selected from a group consisting of thermoplastic elastomers including polyurethanes, styrenic block copolymers, or EPDM.
12 . The method of claim 1 wherein the first and second sheets have a third layer comprising a release layer.
13 . The method of claim 1 wherein the pressure applied is between 20 and 95 psi.
14 . The method of claim 1 wherein at least one layer absorbs the laser energy and converts it to heat.
15 . The method of claim 1 wherein the first sheet and the second sheet form a belt after joining the edge of the first sheet to the edge of the second sheet.
16 . A method for joining a first sheet to a second sheet comprising:
providing a first rigid plate;
providing a thermal conductive layer consisting of a material selected from polyethylene terephthalate (PET), polyimide, or polycarbonate on the first rigid plate;
positioning a first sheet having a polycarbonate layer and a polyurethane layer on the thermal conductive layer;
wherein the polyurethane layer is adjacent to the thermal conductive layer;
positioning a second sheet having a polycarbonate layer and a polyurethane layer on the thermal conductive layer;
wherein the polyurethane layer is adjacent to the thermal conductive layer;
wherein an edge of the of the first sheet abuts an edge of the second sheet;
placing a second rigid plate of transparent material on top of the first and second sheet;
applying pressure to the first and second sheet; and
laser welding the edge of the first sheet to the edge of the second sheet with a first laser.
17 . A method for joining a first sheet to a second sheet comprising:
providing a first rigid plate;
providing a thermal conductive layer consisting of a material selected from polyethylene terephthalate (PET). polyimide, or polycarbonate on the first rigid plate;
positioning the first sheet on the thermal conductive layer;
positioning the second sheet on the thermal conductive layer; wherein an edge of the of the first sheet abuts an edge of the second sheet;
providing a layer of laser energy absorbing material on the first and second sheet;
placing a second rigid plate, wherein the second rigid plate is comprised of transparent material, on top of the first and second sheets;
applying pressure to the first sheet edge and second sheet edge; and
laser welding the edge of the first sheet to the edge of the second sheet with a first laser.