CN100572034C - 一种激光塑料焊接新方法 - Google Patents

一种激光塑料焊接新方法 Download PDF

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CN100572034C
CN100572034C CNB2007100233054A CN200710023305A CN100572034C CN 100572034 C CN100572034 C CN 100572034C CN B2007100233054 A CNB2007100233054 A CN B2007100233054A CN 200710023305 A CN200710023305 A CN 200710023305A CN 100572034 C CN100572034 C CN 100572034C
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laser
welding
plastics
weld seam
shape
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CN101077624A (zh
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王霄
季进清
张惠中
刘会霞
蔡兰
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Jiangsu University
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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
    • 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
    • B29C65/1696—Laser beams making use of masks
    • 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
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/24—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight
    • B29C66/242—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours
    • B29C66/2424—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being a closed polygonal chain
    • B29C66/24249—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being a closed polygonal chain forming a specific polygon not provided for in B29C66/24241 - B29C66/24243
    • 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
    • B29C66/812—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 composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/8126—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 composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/81266—Optical properties, e.g. transparency, reflectivity
    • B29C66/81267—Transparent to electromagnetic radiation, e.g. to visible light
    • 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
    • B29C65/1603—Laser beams characterised by the type of electromagnetic radiation
    • B29C65/1612—Infrared [IR] radiation, e.g. by infrared lasers
    • B29C65/1616—Near infrared radiation [NIR], e.g. by YAG lasers
    • 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
    • B29C65/1664—Laser beams characterised by the way of heating the interface making use of several radiators
    • 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
    • B29C66/71—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 composition of the plastics material of the parts to be joined

Abstract

一种激光塑料焊接新方法，涉及塑料焊接技术领域。本发明是根据激光全息原理，首先利用激光干涉的方法将预知焊缝形状记录下来，再利用激光衍射的方法将焊缝形状的全部信息释放出来，同时使得激光光斑的形状与预知焊缝形状相同，照射两塑料工件接合面后最终达到两种塑料的同步焊接。此方法适用于复杂焊缝的焊接，而且由于不需要激光源和待焊接塑料工件之间的相对运动，具有很高的焊接效率，并很好的解决了传统激光塑料焊接方法所不能解决的问题。

Description

一种激光塑料焊接新方法
技术领域
本发明涉及塑料焊接技术领域，特指一种激光塑料焊接新方法。本发明是根据激光全息原理，首先利用激光干涉的方法将预知焊缝形状记录下来，再利用激光衍射的方法将焊缝形状的全部信息释放出来，使得激光束光斑的形状与预知焊缝形状相同，照射两塑料工件接合面后最终达到两种塑料的同步焊接。此方法具有很高的焊接效率，并很好的解决了复杂焊缝的同步焊接问题。
背景技术
传统的塑料焊接技术包括：超声波焊接、振动焊接、热平板焊接等。激光塑料焊接的优点是树脂降解少，产生的碎屑少，由于激光的非接触性，在焊接过程中不会产生污染。另一个主要优点是激光塑料焊接比其他连接方式所产生的振动应力和热应力小，这样就大大提高了制品或装置内部组件的使用寿命，因此激光塑料焊接方法更适合应用于易损坏的电子传感器、微流体装置、微机电系统。在20世纪70年代，激光开始被应用到塑料焊接上，由于激光塑料焊接技术的独特优势以及激光技术的发展，到了20世纪90年代，激光塑料焊接技术取得了大规模的工业应用。见于文献报道的最早激光塑料焊接应用是在1972年，使用100瓦的CO2激光光源，以每秒10毫米的速度焊接聚乙烯薄板(最大厚度为1.5毫米)。
激光塑料焊接作为一种新型的塑料焊接技术近年来得到了快速的发展，国内外各研究机构对这种技术的方法、工艺、设备都有了较为深入的研究。在用激光焊接两个塑料工件时，常见的方法利用聚焦成一点的激光束二维扫描焊接表面，激光源与待焊工件之间相对运动，最终完成焊接。在焊接过程中容易引起塑料件的翘曲变形，如果焊缝形状较为复杂，则难以精确控制激光源与待焊接工件之间的相对运动。
在激光塑料焊接方法方面：瑞士莱斯特加工技术公司发表的专利号为CN00101924.4的技术：焊接塑料工件或塑料与其他材料的激光焊接方法及装置，就是在焊接方法上进行研究，根据预知焊缝形状设计掩膜板，利用掩膜板遮挡掉激光光束的一部分，能透过激光的掩膜板形状与预知焊缝相同，最后利用透过掩膜板后的光束对塑料进行焊接。其缺点是激光源与待焊接塑料工件之间有速率较高的相对运动，在焊接过程中容易引起塑料工件的翘曲变形。
本发明是调整光路系统，设计全息底版，通过全息底版改变激光光束的光斑形状，使得激光光束的光斑形状与预知焊缝形状一致，并设计了对激光光速透明的夹具，最终完成塑料工件的同步焊接，在焊接过程中激光源与待焊接塑料工件之间没有相对运动，很好的解决了在焊接过程中塑料工件的翘曲变形问题，而且本发明特别适用于焊缝图形较复杂的情况。
发明内容
本发明的目的是提供一种激光塑料焊接新方法。根据激光全息原理，焊缝图形光束与参考光束干涉产生的干涉图记录下焊缝特征的信息，利用衍射技术将焊缝特征的全部信息再次释放出来，即改变激光光斑的形状，使激光光斑形状与预知焊缝形状一致，照射两种塑料接合面，最终对待焊接区域进行同步焊接。
本发明的目的由以下方式实现：
(1)制作记录焊缝特征模型：在对激光光束透明的材料表面上，除了焊缝特征图形区域外，涂上对激光光束不透明的油漆，油漆可以从市场购买。
(2)制作全息底版：全息底版的基本材料为玻璃基板，厚度为1～1.5mm，在玻璃基板的表面上涂镀一层卤化银乳胶细颗粒，厚度为6～15μm。
激光器采用氦氖激光器，氦氖激光器发出的激光光束经反射镜调整光路，再经过分束镜分为两束激光光束：其中一束激光扩大光斑尺寸后照射记录焊缝图形模型表面的焊缝特征形状部分反射后得到焊缝图形光束；另一束激光扩大光斑尺寸后得到参考光束，焊缝图形光束和参考光束在玻璃基板涂镀卤化银乳胶细颗粒的面上干涉，产生干涉图，记录记录下干涉条纹后，再经过理化处理(显影、定影、干燥和密封)后，固定干涉图，全息底版制作完成。制作完成的全息底版相当于一个衍射光栅，因为全息底版由玻璃材料制成，所以具备更高的衍射效率。
(3)进行塑料焊接：在激光焊接塑料时，选用光纤激光器。光纤激光器发出激光光束后，经过一个凸透镜组合扩大激光光束光斑尺寸，光斑尺寸扩大后的激光光束照射全息底版得到激光光束的光斑形状与预知焊缝形状一致，利用最后得到的激光光束照射两个塑料工件的接合面，最终形成焊缝。
附图说明
图1为全息底版制作过程示意图
图2为记录焊缝图形模型示意图
图3为焊接示意图
图4为焊缝示意图
图5为具体实施例记录“凸”字形焊缝图形模型表面尺寸图
1氦氖激光器；2激光光束；3反射镜；4分束镜；5小凸透镜；6大凸透镜；7记录焊缝图形模型；8焊缝特征形状部分；9油漆；10全息底版；11卤化银乳胶细颗粒；12光纤激光器；13激光光束；14夹具；15透光性塑料工件；16吸光性塑料工件；17接合面；18焊缝
具体实施方式
现以“凸”字形焊缝举例。
选择焊接材料：透光性聚氯乙烯(PVC)：长：50mm，宽：50mm，厚：2mm；吸光性聚氯乙烯(PVC)：长：50mm，宽：50mm，厚：2mm。
激光器1采用氦氖激光器，功率：100mW，波长：530nm。激光器12采用光纤激光器，功率：80W，波长：1064nm。
第一步制作记录焊缝特征模型：记录焊缝图形模型的材料为K9玻璃，尺寸：长：50mm，宽：50mm，厚：2mm。除焊缝特征形状部分8以外，在记录焊缝图形模型7表面涂上对激光光束2不透明的油漆9。表面尺寸如图5(单位：mm)。
第二步制作全息底版：全息底版10由玻璃基板制成，尺寸：长：50mm，宽：50mm，厚：1mm。并在玻璃基板表面涂镀一层卤化银乳胶细颗粒11，厚度10μm。
氦氖激光器1发出激光光束2，激光光束2经反射镜3调整光路，再经过分束镜4分为两束激光：
其中一束激光经反射镜3调整光路，经凸透镜组合5，6扩大光斑尺寸(扩至直径：80mm)后照射记录焊缝图形模型7表面的焊缝特征形状部分8反射后得到的激光束为焊缝图形光束。
另一束激光光束经反射镜3调整光路，经凸透镜组合5，6扩大光斑尺寸(扩至直径：80mm)得到参考光束。
焊缝图形光束与参考光束在玻璃基板涂镀卤化银乳胶细颗粒11的面上干涉，产生干涉图，记录下干涉条纹后，再经过理化处理(显影、定影、干燥和密封)后，固定干涉图，全息底版10制作完成。此过程如附图1。
第三步进行塑料焊接：光纤激光器12发出激光光束13，激光光束13经凸透镜组合5，6扩大光斑尺寸后照射全息底版10后得到激光光束的光斑形状与预知焊缝形状相同，光斑直径：80mm，照射两塑料工件15，16的接合面17，照射时间：10s，最终形成焊缝18。理想焊缝宽度为1.3mm。透明夹具14保证了两塑料工件15，16在压力作用下紧密接触。此过程如附图3。

Claims (2)

1、一种激光塑料焊接新方法，其特征在于，按照以下步骤进行：
(1)制作记录焊缝特征模型：在对激光光束透明的材料表面上，除了焊缝特征图形区域外，涂上对激光光束不透明的油漆；
(2)制作全息底版：激光器发出的激光光束经反射镜调整光路，再经过分束镜分为两束激光光束，其中一束激光扩大光斑尺寸后照射记录焊缝图形模型表面的焊缝特征形状区域反射后得到焊缝图形光束；另一束激光扩大光斑尺寸后得到参考光束，焊缝图形光束和参考光束在玻璃基板涂镀卤化银乳胶细颗粒的面上干涉，产生干涉图，玻璃基板厚度为1～1.5mm，卤化银乳胶细颗粒，厚度为6～15μm；记录下干涉条纹后，再经过理化处理后，固定干涉图，全息底版制作完成；
(3)进行塑料焊接：激光器发出激光光束后，经过一个凸透镜组合扩大激光光束光斑尺寸，光斑尺寸扩大后的激光光束照射全息底版得到激光光束的光斑形状与预知焊缝形状一致，激光光束照射两个塑料工件的接合面，最终形成焊缝。
2、权利要求1所述的一种激光塑料焊接新方法，其特征在于：步骤2中激光器采用氦氖激光器，步骤3中激光焊选用光纤激光器。
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