CN100546814C - 用于激光焊接热塑树脂部件的方法和装置 - Google Patents

用于激光焊接热塑树脂部件的方法和装置 Download PDF

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Publication number
CN100546814C
CN100546814C CNB2006101318182A CN200610131818A CN100546814C CN 100546814 C CN100546814 C CN 100546814C CN B2006101318182 A CNB2006101318182 A CN B2006101318182A CN 200610131818 A CN200610131818 A CN 200610131818A CN 100546814 C CN100546814 C CN 100546814C
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China
Prior art keywords
parts
laser beam
extruding force
thermoplastic resin
contact
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Expired - Fee Related
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CNB2006101318182A
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CN1951674A (zh
Inventor
渡边敏雄
中岛毅彦
中村秀生
森博志
藤田进
中谷光伸
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Toyota Motor Corp
EIDP Inc
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Toyota Motor Corp
EI Du Pont de Nemours and Co
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1654—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1654—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined
    • B29C65/1658—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined scanning once, e.g. contour laser welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1677—Laser beams making use of an absorber or impact modifier
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7841—Holding or clamping means for handling purposes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/349—Cooling the welding zone on the welding spot
    • B29C66/3494—Cooling the welding zone on the welding spot while keeping the welding zone under pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8145—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81463—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps comprising a plurality of single pressing elements, e.g. a plurality of sonotrodes, or comprising a plurality of single counter-pressing elements, e.g. a plurality of anvils, said plurality of said single elements being suitable for making a single joint
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/836—Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • B29C66/90—Measuring or controlling the joining process
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    • B29C66/9121—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature
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    • B29C66/91216—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature with special temperature measurement means or methods enabling contactless temperature measurements, e.g. using a pyrometer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/90—Measuring or controlling the joining process
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

用于焊接由热塑树脂材料形成的部件的方法和装置，其能够使焊接强度高并使强度变化小。激光焊接装置使由可透射激光束的透射性热塑树脂形成的第一部件与由可吸收激光束的吸收性热塑树脂形成的第二部件接触，使用激光束熔融所述部件的接触面以使所述部件接合。该激光焊接装置还包括使用从第一部件一侧照射的激光束照射第一和第二部件的至少一个接触面以使所述接触面熔融的激光束生成装置。该装置还包括用于将第一和第二部件挤压在一起的夹紧机构、作为调节装置以用于调节第一和第二部件的挤压力的温度传感器和用于根据温度传感器的输出计算挤压力的个人计算机。通过所计算的挤压力控制夹紧机构。

Description

用于激光焊接热塑树脂部件的方法和装置
技术领域
本发明涉及一种用于激光焊接热塑树脂部件的方法和装置。特别地，本发明涉及一种通过使由可透射激光束的透射性热塑树脂形成的部件与由可吸收激光束的吸收性热塑树脂形成的部件熔融以使它们接合的方法和装置。
背景技术
为响应近年来减小各种领域的元件例如汽车元件的重量和成本的需要，经常利用树脂材料制成这种部件并且将这种部件形成为树脂模制品。当要形成具有复杂形状的树脂模制品时，预先模制多个由树脂模制品制成的构件，然后通过焊接将这些构件接合在一起以便提高生产率。
传统的用于焊接这种树脂模制品的激光焊接装置通过使用光学系统使由激光振荡器生成的激光束聚焦，然后使用该激光束照射待处理部件来焊接所述部件。待处理部件上的可滑动部分设置在处理喷嘴的顶端，该处理喷嘴设置在光学系统的聚焦透镜和待处理的部件之间。还设置压力施加设备以便相对于处理喷嘴顶端的可滑动部分向待处理的部件施加压力(例如，见专利文献1)。
在激光焊接装置的另一示例中，使激光束穿过至少两个工件之一照射所述工件的接触区域，以便熔融所述接触区域并焊接所述工件。该装置包括用于生成激光束的激光束生成装置和球面透镜，该球面透镜设置在激光束离开该激光束生成装置的位置的正下方以使激光束聚焦在接触区域上。该球面透镜适于在可透射激光束的工件的表面上滚动。该装置还包括用于紧靠工件推动球面透镜的推动装置(例如，见专利文献2)。
专利文献1：JP专利公报(Kokai)No.2003-117674A
专利文献2：JP专利公报(Kokai)No.2005-81396A
发明内容
在专利文献1和2的激光焊接装置中，由于通过挤压或推挤提供的夹紧压力是恒定的，所以施加在接合处的焊接界面上的压力变得不足。结果，由于体积收缩的影响而导致强度不足或变化。另外，由于出自激光焊接系统的激光束经过焊接部分并且接合面被焊接之后，焊接部分的压力立刻降低，所以焊接界面处的压力变得不足。因此，由于体积收缩的影响而导致强度不足或强度变化很大。
本发明基于这样的问题而做出，本发明的一个目的是提供一种用于激光焊接热塑树脂部件的方法和装置，其可通过在使用激光束照射两个部件以便焊接期间适当地控制所述部件之间的接触压力(夹紧压力)来提供高焊接强度和并使强度变化较小。
为实现该目的，本发明提供了一种用于激光焊接热塑树脂部件的方法，该方法包括使由可透射激光束的透射性热塑树脂形成的第一部件与由可吸收激光束的吸收性热塑树脂形成的第二部件相接触，使用激光束熔融接触面以使所述部件相接合。该激光焊接方法还包括挤压这两个部件，使用从该第一部件一侧照射的激光束照射这两个部件的接触面，熔融这两个部件的至少一个接触面，焊接这两个部件同时调节施加在该第一部件和该第二部件上的挤压力。
根据结构如上所述的本发明的用于激光焊接热塑树脂部件的方法，将由热塑树脂形成的第一部件和第二部件相堆叠，从第一部件一侧照射激光束同时调节这两个部件的接触面处的挤压力，通过加热和熔融所述接触面来焊接这两个部件。因此，可通过例如在加热部件时轻微挤压所述部件、当接合面处的树脂熔融时逐渐增加挤压力以及在此后强有力地挤压所述部件，来减小树脂熔融部分的体积收缩。由于这两个部件的接合面均匀并且焊接状态稳定，所以可获得大的焊接强度，并且可使强度的变化最小。
对挤压力的调节意味着可适当地调节焊接部分的焊接强度。例如，该调节是指在熔融期间相对于初始挤压力增加挤压力以使两个部件紧密连接，并在冷却时进一步增加挤压力。该调节还可以指在熔融期间相对于该挤压力增加挤压力以使两个部件紧密连接，并在冷却时降低到初始挤压力。对挤压力的调节是根据待焊接的两个部件的形状、体积等适当地设定的。
在本发明的激光焊接方法的优选实施例中，根据对因激光束照射而熔融的接触面熔融部分的温度的检测来进行挤压力调节。根据如此构成的激光焊接方法，可通过检测激光束照射的熔融温度来检测熔融部分的膨胀状态。通过执行反馈控制以根据膨胀率增加挤压力，可防止两个部件由于熔融部分膨胀而分离或者两个部件之间由于冷却时的体积收缩而出现空隙。因此，可提高焊接强度，并减小强度的变化。优选地，在激光束照射期间减小挤压力，当熔融开始且温度增加时逐渐增加挤压力，然后当熔融部分冷却并且温度下降时进一步增加挤压力。
在本发明的激光焊接方法的另一优选实施例中，根据对因激光束照射而熔融的接触面熔融部分的压力的检测来进行挤压力调节。根据如此构成的激光焊接方法，可通过检测当接触面附近的区域因激光束照射而熔融时发生的压力增加或者当熔融部分冷却时发生的压力降低，来检测熔融部分的膨胀和收缩状态。通过执行反馈控制以根据膨胀率改变挤压力，可防止两个部件由于熔融部分膨胀而分离或者两个部件之间由于冷却时的体积收缩而出现空隙，从而增加焊接部分的密(集)度。因此，可提高焊接强度，并减小强度变化。优选地，在激光束照射期间减小加压力，当熔融开始且温度增加时逐渐增加挤压力，然后当熔融部分冷却并且温度降低时进一步增加挤压力。
本发明的用于激光焊接热塑树脂部件的装置是这样一种装置，该装置用于使由可透射激光束的透射性热塑树脂形成的第一部件与由可吸收激光束的吸收性热塑树脂形成的第二部件相接触，使用激光束熔融所述部件的接触面以使所述部件相接合。该装置包括：用于使用从第一部件一侧照射的激光束来照射第一和第二部件的至少一个接触面以使至少一个接触面熔融的激光束生成装置、用于将第一和第二部件挤压在一起的挤压装置以及用于调节施加在第一和第二部件上的挤压力的调节装置。
根据这样构造的用于激光焊接热塑树脂部件的装置，使第一部件和第二部件相互接触，在将这两个部件压在一起的同时使用从第一部件一侧照射的激光束照射接触面，熔融至少一个接触面。在熔融开始之后，增加挤压力以防止这两个部件分离。当熔融部分冷却时进一步增加挤压力，以防止在熔融部分凝固时出现空隙等并增加熔融部分的密度，从而增加焊接强度。同样，可减小由于部件的形状等导致的强度变化。
该激光焊接装置优选地包括温度检测装置，以用于检测由于第一部件和第二部件上因激光束照射而熔融的部分的温度，其中调节装置根据该温度检测装置的输出来调节施加在第一部件和第二部件上的挤压力。另外优选地，该激光焊接装置包括压力检测装置，以用于检测第一部件和第二部件上因激光束照射而熔融的部分的压力，其中调节装置根据该压力检测装置的输出来调节施加在第一部件和第二部件上的挤压力。
这样，可根据温度或压力检测这两个部件的接触面附近区域的熔融状态，并可通过根据所检测的温度或压力计算适合于两个部件的挤压力来调节施加在这两个部件上的挤压力。从而，可通过当在熔融期间体积膨胀时使用增大的挤压力强有力地使所述两个部件贴附并且当因熔融部分冷却体积减小时进一步增加挤压力，来防止在熔融部分凝固时出现空隙。这样，由于可通过检测熔融部分的温度或压力以施加合适的挤压力，所以可提高焊接强度并可减小强度的变化。
该激光焊接装置包括用于移送激光束发生器的移送装置。该挤压装置包括用于挤压第一部件和第二部件的多个挤压部件。优选在激光束发生器的移送期间调节所述多个挤压部件的挤压力。根据此结构，在激光束发生器的移送期间移送熔融部分，并且可根据熔融部分的状态通过所述多个挤压部件调节用于使两个部件贴附的挤压力。因此，当待焊接部分长而连续时可获得均匀的焊接状态，从而提高焊接强度并减小强度的变化。
所述挤压装置可使用弹簧压力、油压和/或气压。通过挤压装置使用弹簧压力、油压和/或气压，可使这两个部件稳定地相互贴附。特别地，通过油压或气压进行挤压力调节是优选的，因为这样能进行平滑的调节和细微的挤压力控制。
在根据本发明的激光焊接方法和装置中，用作可透射激光束的透射性热塑树脂的树脂类型没有特别的限制，只要该树脂是热塑性的并且能够透射作为热源的激光束即可。示例包括诸如尼龙6(PA6)或尼龙66(PA66)的聚酰胺(PA)、聚乙烯(PE)、聚丙烯(PP)、苯乙烯-丙烯腈共聚物、聚对苯二甲酸乙二醇酯(PET)、聚苯乙烯、ABS、聚甲基丙烯酸甲酯(PMMA)、聚碳酸酯(PC)以及聚对苯二甲酸丁二醇酯(PBT)。可根据需要添加着色剂或诸如玻璃纤维或碳纤维的加强纤维。短语“透射激光束”是指激光束透射率优选地为20％或更大，更优选为50％或更大，再优选为80％或更大，最优选为90％或更大。
用作可吸收激光束的吸收性热塑树脂的树脂类型没有特别的限制，只要该树脂是热塑性的并且能够吸收作为热源的激光束而使激光束不能透射即可。示例包括诸如尼龙6(PA6)或尼龙66(PA66)的聚酰胺(PA)、聚乙烯(PE)、聚丙烯(PP)、苯乙烯-丙烯腈共聚物、聚对苯二甲酸乙二醇酯(PET)、聚苯乙烯、ABS、聚甲基丙烯酸甲酯(PMMA)、聚碳酸酯(PC)、聚对苯二甲酸丁二醇酯(PBT)和PPS，其中混合有预定的着色剂，例如碳黑、染料或颜料。可根据需要添加加强纤维，例如玻璃纤维或碳纤维。短语“吸收激光束”是指激光束透射率优选地为10％或更小，更优选为5％或更小，再优选为1％或更小。
对于透射性热塑树脂部件和吸收性热塑树脂部件所使用的树脂组合，优选该组合为彼此相容的树脂的组合。示例除了包括相同类型的树脂的组合例如尼龙6和尼龙6或者尼龙66和尼龙66之外，还包括尼龙6和尼龙66、PET和PC以及PC和PBT的组合。
在本发明的激光焊接方法和装置中，例如，可根据可透射激光束的透射性树脂材料的吸收光谱、厚度(透射长度)等，适当地选择照射所述两个部件的接触面的激光束的类型。示例包括Nd:玻璃(钕3+:玻璃)激光、Nd:YAG(钕3+:YAG)激光、红宝石激光、氦氖激光、氪激光、氩激光、H2激光、N2激光和半导体激光。优选的激光包括YAG:钕3+激光(激光束的波长：1060nm)和半导体激光(激光束的波长：500～1000nm)。
优选地，激光束的输出功率为10～900W。如果激光束的输出功率小于10W，则输出功率过低而难以熔融树脂材料的对接面。如果输出功率超过900W，则输出功率过大并且树脂材料可能会气化或性质变化。
因此，根据本发明的用于激光焊接热塑树脂部件的方法和装置，可实时控制挤压力以便使用合适的挤压力挤压待焊接的已处理部件。因此，可校正熔融部分的体积膨胀和焊接部分的体积收缩，从而提高焊接强度并减小焊接强度的变化。
附图说明
图1示出根据本发明一种实施例的用于激光焊接热塑树脂部件的装置的主要部分；
图2示出图1的装置的操作；
图3示出根据本发明另一实施例的用于激光焊接热塑树脂部件的装置的主要部分。
具体实施方式
下面，将参照附图详细说明实施本发明的用于激光焊接热塑树脂部件的方法的激光焊接装置的一种实施例。图1示出根据本实施例的用于激光焊接热塑树脂部件的装置的主要部分。图2示出图1的装置的操作。
在图1中，在根据本实施例的激光焊接装置1内，使由可透射激光束的透射性热塑树脂制成的第一部件2与由可吸收激光束的吸收性热塑树脂制成的第二部件3相接触，使用激光束熔融接触面4以使所述部件接合。激光焊接装置1包括激光束发生器10，以用于使用激光束R从可透射激光束的第一部件2一侧照射这两个部件2和3的接触面4。
激光束发生器10包括激光振荡器11和经由光纤与该激光振荡器连接的激光头12。从激光头发射的激光束例如是半导体激光束，该激光束的波长为940nm，并且优选其输出功率在大约10～900W之间。激光头12上连接有移送机构13，该移送机构用于在焊接期间以例如大约0.1～5m/min的处理速度移送该激光头。对于移送机构13，可使用合适的结构，例如其中激光头12上连接工业机器人的结构、其中使用二维台架或三维台架移送部件的结构、其中使用光学透镜和镜件的组合控制焦点的结构或者其中使用多个激光头同时照射多个部位的结构。
形成第一部件2并且可透射激光束的透射性热塑树脂材料的激光束透射率优选为20％或更大，更优选为50％或更大，再优选为80％或更大，尤其优选为90％或更大。形成第二部件3并且可吸收激光束的吸收性热塑树脂材料的激光束透射率优选为10％或更小，更优选为5％或更小，再优选为1％或更小。由于形成第二部件3的树脂材料透射的激光束非常少，所以该树脂材料可认为是非透射性热塑树脂材料。第二部件3在被激光束照射时几乎不透射激光束而是吸收激光束，因此，激光束的能量积聚在第二部件内，由此生热。
该激光焊接装置1包括作为挤压装置的夹紧机构，以用于挤压第一部件2和第二部件3并使这两个部件紧密贴附。夹紧机构20是用于将所述两个部件2和3挤压在一起的机构，该机构能够沿接触面4的方向通过从两个部件外部挤压这两个部件来调节接触压力。在本实施例中，从液压系统向气缸供给压力油，以使气缸内的活塞滑动并使两个部件2和3相互紧密地贴附。
附图中示出的夹紧机构20包括三对相对的挤压部件。一对挤压部件21、21通过从上方和下方夹挤两个部件的左手部分来挤压这两个部件。中间的一对挤压部件22、22通过从上方和下方夹挤两个部件的中间部分来挤压这两个部件。挤压部件23、23通过从上方和下方夹挤两个部件的右手部分来挤压这两个部件。优选地，挤压部件由具有足够硬度的材料例如金属形成。挤压部件的数量是根据两个部件的形状或大小适当设定的。
夹紧机构20构造成所述三对挤压部件的挤压力可通过使用例如液压缸来个别地调节。假设使两个堆叠的部件相贴附的方向为正，则夹紧机构的挤压力不会提供沿负方向(使两个部件分离的方向)的挤压力。即，夹紧机构20用于通过沿正方向调节挤压力来提供适合于接触面的熔融状态的挤压力。
激光焊接装置1包括用于检测第一部件2和第二部件3上因激光束照射而产生的熔融部分温度的温度检测装置(温度传感器)31，以作为调节挤压力的装置30。该温度传感器31检测从透射性的第一部件2侧面的熔融部分发出的热射线S，例如在监控器上显示该热射线S以便测量温度。将所测的温度输入例如个人计算机(PC)32。PC 32根据所测的温度计算合适的挤压力，并反馈回给夹紧机构20，由此实时控制挤压力。因此，根据所测的温度计算从夹紧机构20提供给两个部件的挤压力，然后进行反馈控制。温度传感器31联接到可沿水平方向移动的移送机构33，从而可检测接触面上熔融部分的温度状态。尽管温度传感器可从斜上方检测温度以便不影响激光头的移送，但是优选从正上方进行温度检测。
用于检测熔融部分的温度、根据该温度计算夹紧机构20的适当挤压力并且使用由此计算的挤压力将两个部件2和3挤压在一起的实时控制设备可使用预先准备的压力改变程序，由此根据所获得的熔融部分的状态来计算挤压力以控制夹紧机构。
下面将说明结构如上所述的实施例的激光焊接装置的操作。将第一部件2和第二部件3堆叠，然后通过夹紧机构20挤压这两个部件2和3，从而使它们牢固地相互贴附。所述两个部件堆叠成使得透射性的部件2朝向激光头12。这里，假设夹紧机构20的挤压力为F1，其约为使得所有挤压部件能使所述两个部件2和3轻微地相互贴附。
起动激光束生成装置的激光振荡器11，并使用从激光头12发射的激光束R照射这两个部件的焊接部分。由于通过激光头内的照射透镜使激光束R聚焦在接触面上，所以在接触面4附近的区域产生热，该接触面4为吸收激光束的第二部件3的上部部分。当向接触面提供预定量的激光能量时，第二部件3的接触面4附近的区域熔融，同时第一部件2的接触面熔融。结果，两个熔融部分4a熔合在一起，由此第一部件2和第二部件3熔合在一起。这样，可通过在两个部件的接触面4熔融时移送激光头12以延长熔融部分4a来使这两个部件的熔融部分连续。
温度传感器31通过移送机构33移送并且检测从熔融部分发出的热射线S，由此检测温度。当检测到所测温度高于预定温度并且接触面附近的区域熔融时，将所测温度输入PC 32以计算挤压力F2，该挤压力大于初始挤压力的值F1。将如此计算出的挤压力F2反馈给夹紧机构20，该机构将位于温度检测部分附近的挤压部件21、21的挤压力F1增大到F2。由于挤压力增加，所以可防止这两个部件由于熔融部分的体积膨胀而分离。
如图2所示，当熔融部分随着激光头12的移送而延伸时，初始的熔融部分开始冷却。当温度传感器31检测到熔融部分的冷却时，将温度的下降输入PC。根据该温度的下降，PC计算挤压力F3-该挤压力F3大于以前提供的挤压力F2，然后将其反馈给夹紧机构20。夹紧机构20将挤压部件21的挤压力F2增大到所算出的挤压力F3，由此可防止因体积减小导致在熔融部分内出现空隙，该体积减小是伴随熔融部分的收缩发生的。
当通过移送机构13移送激光头12并且使熔融部分4a延长时，初始熔融部分逐渐冷却。当温度传感器31检测到该冷却状态时，增加靠近冷却部分的挤压部件的挤压力，由此可防止在熔融部分内出现空隙。当依次增加施加在所有连续熔融部分上的挤压力并且当冷却时所有熔融部分凝固时，两个部件的焊接完成。即，构成调节装置30的PC 32计算提供给多个挤压部件21～23的挤压力，从而随着激光头12的移送，挤压力从F1增加到F2并进一步增加到F3。
从而，检测了通过挤压力F1连接的两个部件2和3因激光束照射而产生的温度变化，并且当接触面熔融时将初始的小挤压力F1增加到挤压力F2。随着熔融部分的冷却，挤压力增加到更大的挤压力F3，以使挤压部件21～23具有合适的挤压力。因此，由于可使焊接状态均匀并使熔融部分保持较高的密度，所以可增加焊接强度并减小焊接强度的变化。
下面将参照附图3详细说明本发明的另一实施例。图3示出本发明的激光焊接装置另一实施例的主要部分。与上述实施例相反，本实施例通过检测指示熔融部分状态的压力来调节挤压力，在该熔融部分处两个部件的接触面熔融。其它基本等效的元件用相同标号指示。
在图3中，作为用于调节夹紧机构20的挤压力的装置40，本实施例的激光焊接装置1A包括压力检测装置(压力传感器)41～43，以用于检测第一部件2和第二部件3上被激光束照射的熔融部分的压力。这些压力传感器41～43安装在例如挤压部件21～23的活塞部，并且根据由于通过激光束R熔融的熔融部分4a的体积膨胀而出现的变形经由压力传感器例如应变计检测压力。将如此检测的压力输入运算装置例如个人计算机(PC)44，在该处根据压力计算合适的挤压力，并将其反馈给夹紧机构20以实时控制挤压力。
在本实施例的如此构造的激光焊接装置1A内，当通过激光束R照射而熔融两个部件2和3的接触面4时，安装在挤压部件21处的压力传感器41的输出因熔融部分4a的体积膨胀而改变。具体地，当挤压部件21以初始挤压力F1进行挤压时，压力传感器41输出的挤压力由于伴随体积膨胀的压力的增加而增大。这样，在检测到被激光束R照射的部分已熔融时，PC 44根据压力传感器41的输出计算出合适的挤压力F2，该挤压力F2大于挤压力F1。将如此计算的挤压力F2反馈给夹紧机构20，该夹紧机构然后将位于被检测压力的部分附近的挤压部件21的挤压力F1增加到F2。挤压力的增加可防止两个部件因熔融部分4a的体积膨胀而分离。
当熔融部分4a随着激光头12的移送而延长时，初始熔融的部分开始冷却。即，当因熔融而膨胀的熔融部分冷却并由于体积收缩而变为熔融部分4b时，压力传感器41检测到该熔融部分4a的冷却。将压力的降低输入PC 44。然后，PC 44根据该压力的降低计算挤压力F3-该挤压力F3大于以前提供的挤压力F2，然后将其反馈给夹紧机构20。夹紧机构20将挤压部件21的挤压力F2增大到F3。
由于挤压机构20将挤压部件21的挤压力F2增加到计算出的挤压力F3，所以可防止由于体积减小而导致在焊接部分4b内出现空隙，该体积减小是伴随熔融部分4a的收缩发生的。当通过移送机构13移送激光头12并且熔融部分4b延长时，初始熔融部分逐渐冷却。当通过温度传感器检测到冷却状态时，增加靠近被检测部分的挤压部件的挤压力，从而防止在熔融部分4b内出现空隙。对于所有连续的熔融部分依次增加挤压力，所述熔融部分冷却并凝固成焊接部分，从而两个部件的焊接完成。
因此，在此实施例中同样可通过检测所贴附的两个部件的压力状态、当接触面熔融时将提供给多个挤压部件的挤压力从初始的小挤压力F1增大到F2以及当熔融部分冷却时将挤压力进一步增大到更大的挤压力F3，来使焊接状态均匀并使焊接部分4b保持高的密度。因此，焊接强度变高，并且可减小焊接强度的变化。
尽管上文已明确说明了本发明的实施例，但本发明并不局限于上述实施例。可在不背离本发明的精神的情况下，在权利要求的范围内进行各种不同的改变或变型。例如，尽管说明了其中通过从上方和下方夹挤来挤压两个部件以将这两个部件挤压在一起的结构，但也可将这两个部件堆叠在固定基座等上，然后可从上方提供挤压力。
很明显，除了上述热塑树脂外，热塑树脂的示例还包括例如通用热塑树脂、通用工程塑料、超级工程塑料和热塑弹性体。构成第一部件并可透射激光束的透射性热塑树脂优选具有高透射率，而构成第二部件并可吸收激光束的吸收性热塑树脂优选具有低透射率。优选地，这两个部件之间的透射率相差很大。
工业适用性
本发明通过选择由透射性热塑树脂形成的第一部件和由吸收性热塑树脂形成的第二部件-所述热塑树脂具有不同的激光束透射率，可使焊接强度较高并且使强度变化较小。由于本发明防止在焊接部分出现毛边等，所以可提高焊接部分的质量。本发明可应用于各种不同类型的树脂和树脂元件的焊接。

Claims (9)

1.一种用于激光焊接热塑树脂部件的方法，该方法包括使由可透射激光束的透射性热塑树脂形成的第一部件与由可吸收激光束的吸收性热塑树脂形成的第二部件相接触，使用激光束熔融所述部件的接触面以使所述部件相接合，所述方法还包括：
将该第一部件和该第二部件压在一起；
使用从该第一部件一侧照射的激光束照射这两个部件的接触面；
熔融这两个部件的至少一个接触面；以及
焊接这两个部件并调节施加在该第一部件和该第二部件上的挤压力，
其特征在于，
根据对因激光束照射而熔融的接触面熔融部分的温度的检测来调节挤压力。
2.根据权利要求1的用于激光焊接热塑树脂部件的方法，其特征在于，根据对因激光束照射而熔融的接触面熔融部分的压力的检测来调节挤压力。
3.根据权利要求1的用于激光焊接热塑树脂部件的方法，其特征在于，在调节挤压力时，当检测到的温度高于预定值时，挤压力增大到第一挤压力，并且当判定检测到的温度正在下降时，挤压力进一步增大到第二挤压力。
4.一种用于激光焊接热塑树脂部件的装置，其中使由可透射激光束的透射性热塑树脂形成的第一部件与由可吸收激光束的吸收性热塑树脂形成的第二部件相接触，使用激光束熔融所述部件的接触面以使所述部件相接合，该装置包括：
激光束生成装置，该生成装置用于使用从第一部件一侧照射的激光束来照射该第一部件和该第二部件的接触面以使至少一个接触面熔融；
用于将该第一部件和该第二部件压在一起的挤压装置；以及
用于调节施加在该第一部件和该第二部件上的挤压力的调节装置，
其特征在于，
该装置还包括用于检测所述第一部件和所述第二部件上因激光束照射而熔融的熔融部分的温度的温度检测装置，
其中所述调节装置根据该温度检测装置的输出来调节施加在该第一部件和该第二部件上的挤压力。
5.根据权利要求4的用于激光焊接热塑树脂部件的装置，其特征在于，该装置包括用于检测所述第一部件和所述第二部件上因激光束照射而熔融的熔融部分的压力的压力检测装置，
其中所述调节装置根据该压力检测装置的输出来调节施加在该第一部件和该第二部件上的挤压力。
6.根据权利要求4的用于激光焊接热塑树脂部件的装置，当所述温度检测装置的输出高于预定值时，所述调节装置将挤压力增大到第一挤压力，并且当所述温度检测装置的输出下降时，所述调节装置将挤压力进一步增大到第二挤压力。
7.根据权利要求4到6中任一项的用于激光焊接热塑树脂部件的装置，其特征在于，该装置包括用于移送激光束生成装置的移送装置，
其中所述挤压装置包括多个挤压所述第一部件和所述第二部件所用的挤压部件，并根据所述激光束生成装置的移送来调节施加在该多个挤压部件上的挤压力。
8.根据权利要求4到6中任一项的用于激光焊接热塑树脂部件的装置，其特征在于，所述挤压装置使用弹簧压力、油压和气压中的一种或多种。
9.根据权利要求7的用于激光焊接热塑树脂部件的装置，其特征在于，所述挤压装置使用弹簧压力、油压和气压中的一种或多种。
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