Method and apparatus for heat bonding

Claim 1

Apparatus for making a substantially rigid heat bonded article from a plurality of cooperating members comprising: a rigid backing member including a workpiece cavity therein having a rigid article receiving surface; a rigid top member adapted for pivotal movement with respect to the backing member; a flexible heating blanket comprising a flexible, resilient rubber-like material having embedded therein an electric resistance heater, the blanket being preshaped to reflect contour of the article to be made, being positioned in spaced apart relationship with the article receiving surface, and being adapted to contact and to provide heat to at least one of the cooperating members of the article; and fluid pressure means comprising a resilient sponge member having a plurality of discrete cells closed one from another to retain in each compartment a compressible fluid, the fluid pressure means being carried by the top member and including a pressure transmitting surface for location in juxtaposition with the workpiece cavity when the top member is pivoted toward the backing member to press toward one another the heating blanket and the article receiving surface.

Claim 3

A method for bonding into a substantially rigid article a plurality of cooperating members, each having an interface surface which cooperates with an interface surface of another of the members, comprising the steps of: placing cooperating interface surfaces in juxtaposition one with the other with a bonding material at the interface surfaces to provide a preliminary assembly; placing a first portion of the preliminary assembly on a rigid backing member surface; forming a flexible heating blanket preshaped to reflect contour of the article to be bonded, the blanket comprising a flexible, resilient rubber-like material having embedded therein an electric resistance heater; placing the flexible heating blanket over a second portion of the assembly opposite the first portion; applying fluid pressure to the heating blanket through compression of a resilient sponge member having a plurality of discrete cells closed one from another and retaining a compressible fluid, thereby deforming the heating blanket to the contour of the second portion of the assembly, to press: a. the heating blanket against the assembly, b. the first portion of the assembly against the backing member surface, and c. the interface surfaces together; while at the same time, applying heat to the assembly sufficient to bond the surfaces with the bonding material.

Claim 4

A method for bonding into a substantially rigid article a plurality of cooperating members, each having an interface surface which cooperates with an interface surface of another of the members, comprising the steps of: placing cooperating interface surfaces in juxtaposition one with the other with a bonding material at the interface surfaces to provide a preliminary assembly; placing a first portion of the preliminary assembly on a rigid backing member surface; forming a flexible heating blanket preshaped to reflect contour of the article to be bonded, the blanket comprising a flexible, resilient rubber-like material having embedded therein an electric resistance heater; placing the flexible heating blanket over a second portion of the assembly opposite the first portion; applying fluid pressure to the heating blanket through compression of a resilient sponge member having a plurality of discrete cells closed one from another and retaining a compressible fluid, thereby deforming the heating blanket to the contour of the second portion of the assembly, to press: a. the heating blanket against the assembly, b. the first portion of the assembly against the backing member surface, and c. the interface surfaces together; while at the same time, applying heat to the assembly sufficient to bond the surfaces with the bonding material.