Welding plastics with a heater. Encyclopedia of radio electronics and electrical engineering
Encyclopedia of radio electronics and electrical engineering / Ham Radio Technologies
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An amateur practitioner has to make cases for his designs. When making a plastic case, it is best to do this by welding. Welding is performed using a heater, which is a V-shaped tip made of nichrome. To obtain a durable weld, it is necessary to withstand the temperature and thermal conditions. This requires a power regulator, the electrical circuit of which is shown in the figure.
The power regulator contains a step-down transformer T1, a rectifier on diodes VD1-VD8, a regulator on a transistor VT1 and a resistor R1 included in the diagonal of the rectifier bridge. The variable resistor R1 regulates the heating of the tip RH Within a wide range.
Details. Transformer TS-180 (from old tube TVs). All windings are removed, except for the network ones, the secondary winding is wound with 2x8 turns with 02,2 mm wire.
Load RH - V-shaped tip made of nichrome 01,2 ... 1,5 mm, mounted on a heat-resistant insulating material, equipped with a convenient handle.
Diodes VD1-VD8 types D242A, D246A, D247 are selected with close values of the forward voltage drop.
Transistor VT1 type GT806A-GT806D, P210V is installed on a radiator with an area of 25 cm2.
Resistor R1 type PPZ-12.
Exploitation. If the temperature of the tip is a few degrees higher, the plastic burns; if it is lower, it does not melt. The parts to be welded are joined with a gap of no more than a millimeter. The heated tip is inserted between the edges and moved along them. In addition to translational movement along the seam, the tip for high-quality mixing and heating of the material is moved up and down so that the trajectory of its movement resembles a sinusoid. Then the seam is welded from the back. When welding butt or at an angle, it is necessary to create the desired pressure. To do this, it is necessary to press on the molten mass with a rod-crusher made of metal with a section of 3x5 mm and a length of 100 mm with a comfortable handle. This achieves the strength of the seam, approaching the strength of the base material.
Author: V.F. Yakovlev
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