CN101291798A - 用于激光焊接三个聚合物层的方法以及由该方法生产的制品 - Google Patents

用于激光焊接三个聚合物层的方法以及由该方法生产的制品 Download PDF

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CN101291798A
CN101291798A CNA2006800389494A CN200680038949A CN101291798A CN 101291798 A CN101291798 A CN 101291798A CN A2006800389494 A CNA2006800389494 A CN A2006800389494A CN 200680038949 A CN200680038949 A CN 200680038949A CN 101291798 A CN101291798 A CN 101291798A
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polymer film
thin polymer
laser
poly
composition surface
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H·莫里
K·纳卡吉马
H·纳卡穆拉
M·纳卡塔尼
H·苏米
T·瓦塔纳贝
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Toyota Motor Corp
EIDP Inc
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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
    • 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
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
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    • 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
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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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
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
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Abstract

一种用激光辐射将第一聚合物物体焊接到第二聚合物物体的方法，其中第一聚合物物体对于该激光辐射是相对透明的并且第二物体对于该激光辐射是相对不透明的，第一和第二物体每个具有接合面，所述第一物体具有相对于其所述接合面的碰撞面，所述方法包括如下步骤：(1)将第一物体的接合面与聚合物薄膜的一面物理接触，并且第二物体的接合面与聚合物薄膜的另一面物理接触，形成在第一物体、第二物体和聚合物薄膜之间的接合点；以及(2)用所述激光辐射辐照所述第一和第二物体和聚合物薄膜使所述激光辐射碰撞该碰撞面，穿过所述第一物体和聚合物薄膜并且辐照所述第二物体的所述接合面，致使所述第一和第二物体在接合面的接合点处被焊接，其中该聚合物薄膜在该激光辐射波长下具有5％或更小的吸收率。

Description

用于激光焊接三个聚合物层的方法以及由该方法生产的制品
技术领域
本发明涉及一种激光焊接聚合物物体的方法。
背景技术
经常希望生产可以机械地组合成更复杂部件的模塑聚合物部件。传统上，已经通过胶粘或螺钉或应用咬合装配(snap-fit)连接或使用化学方法例如胶粘剂将塑料部件组合。这些方法具有的缺点是会给安装过程增加复杂的额外步骤，咬合装配连接经常并非不透气和不透液的，并且可能需要复杂的设计。较新技术是振动和超声波焊接，但是这些也需要复杂的部件设计和焊接设备。此外，由该方法导致的摩擦会产生可能污染部件内部的灰尘。当包括灵敏的电气或电子组件时这尤其成问题。
新近发展的技术是激光焊接。在该方法中，两个要连接的聚合物物体在所使用的激光波长下具有不同的光透射水平。一个物体对于该激光波长至少是部分透明的(并被称作“相对透明的”物体)，而第二部件吸收很大部分的入射辐射(并被称作“相对不透明的”物体)。每一物体具有接合面(faying surface)并且相对透明的物体具有相对于其接合面的碰撞面。使所述接合面接触由此形成接合点(juncture)。将一束激光束对准相对透明的物体的碰撞面使之穿过第一个物体并且辐照第二物体的接合面，致使第一和第二物体在接合面的接合点被焊接。一般性地，参见U.S.5,893,959，其引入本文作为参考，和JP S60-214931 A和JPS62-142092 A。该方法可以很清洁、简单和快速而且提供非常强的、可容易再现的焊接和较大的设计灵活性。
然而，在高激光输出功率时，可能很难产生具有较好强度的焊接，因为某些材料在高功率下可能开始燃烧，这会导致焊接强度的降低。很期望获得一种即使当使用高激光输出功率时仍有效地激光焊接制品的方法。
JP 2003-181931 A公开了一种将两个在用于焊接的激光波长下对光是透明的物体激光焊接在一起的方法，该方法中将一种在用于焊接的波长下吸收红外辐射的非常薄的薄膜放置在两个物体之间，在所放置的位置点处，物体将被焊接在一起。该薄膜吸收激光辐射并且熔化，从而作为胶粘剂将两个物体连接在一起。
发明概述
在这里公开和要求保护一种使用激光辐射焊接第一聚合物物体和第二聚合物物体的方法，其中第一聚合物物体对于该激光辐射是相对透明的并且第二物体对于该激光辐射是相对不透明的，第一和第二物体每个具有接合面，所述第一物体具有相对于其所述接合面的碰撞面，所述方法包括如下步骤：(1)将第一物体的接合面与聚合物薄膜的一面物理接触，并且第二物体的接合面与聚合物薄膜的另一面物理接触，形成在第一物体、第二物体和聚合物薄膜之间的接合点；以及(2)用所述激光辐射辐照所述第一和第二物体和聚合物薄膜使所述激光辐射碰撞该碰撞面，穿过所述第一物体和聚合物薄膜并且辐照所述第二物体的所述接合面，致使所述第一和第二物体在接合面的接合点处被焊接，其中该聚合物薄膜在该激光辐射波长下具有5％或更小的吸收率。
附图说明
图1(a-1)是用于激光焊接方法的相对透明的物体的顶视图。
图1(a-2)是用于本发明方法的聚合物薄膜的视图。
图1(a-3)是用于激光焊接方法的相对不透明的物体的顶视图。
图1(b)是与聚合物薄膜物理接触的相对透明的物体和相对不透明的物体的顶视图。
图2是被激光焊接的两个试件的顶视图。
图3(a)是被激光焊接的两个试件的侧视图。
图3(b)是本发明方法制备的激光焊接物体的视图。
图4是显示按照本发明和比较例由激光焊接形成的制品的焊接强度作为激光能量的函数的图表。
发明详述
本发明涉及一种将相对透明的物体和相对不透明的物体激光焊接在一起的方法，其中在两个物体之间在将制品焊接在一起的区域(即它们的接合面)处放置聚合物薄膜。该薄膜的存在减少了当它们在高激光能量焊接时将出现的所述物体燃烧的可能性。这会导致当使用高能量时具有改善强度的焊接，由此增加焊接过程的灵活性。
用于本发明的聚合物薄膜具有在该被用来焊接的激光的波长下小于或等于大约5％、或优选小于或等于大约3％或更优选小于或等于大约1％的吸收率。在给定波长下的吸收百分率可以通过从100％中减去薄膜在该波长下的透射百分率和反射百分率来计算。透射百分率和反射百分率可以使用任何适当的方法测量，包括可商购的分光光度计。在不同仪器给出该薄膜吸收百分率的不同结果的情况下，应当用Shimadzu Corp.UV3100 UV-VIS-NIR分光光度计来测量。
该聚合物薄膜优选具有小于大约100微米、或更优选大约1至大约50微米、更优选大约1到大约30微米、更优选大约3到大约20微米、或更更优选大约5到大约18微米的厚度。如果该薄膜太薄，它会很难处理。如果它太厚，如果该薄膜吸收过多的激光辐射，该薄膜的存在有时会降低激光焊接的效果。优选地，聚合物薄膜由具有小于相对透明和/或相对不透明的物体的材料的导热率的材料制成，因为这会得到更大的焊接强度。
该聚合物薄膜优选由热塑性聚合物制成。适当的热塑性聚合物的例子包括但不限于聚酯例如聚(对苯二甲酸乙二醇酯)(PET)、聚(对苯二甲酸丙二醇酯)(PTT)、聚(对苯二甲酸丁二醇酯)(PBT)、聚(萘二甲酸乙二酯)(PEN)、和聚(1，4-环己烷二甲醇对苯二甲酸酯)(PCT))；聚碳酸酯；聚酰胺、聚苯乙烯；和聚(甲基)丙烯酸酯(例如聚(甲基丙烯酸甲酯))。
该薄膜可以通过任何适当的成膜方法例如单-轴延伸(single-axisextension)方法、双-轴延伸(double-axis extension)方法、膨胀模塑(inflationmolding)法、片材铸塑(sheet casting)法、按压(pressing)法等等来生产。
该相对不透明的物体和相对透明的物体可以包括一种或多种聚合物树脂。该一种或多种聚合物树脂优选包括热塑性聚合物。该聚合物树脂可以包括聚合物，其包括但不限于，聚酯(包括芳香族、半芳香族、和脂族聚酯)；液晶聚合物(包括液晶聚酯)；聚酰胺(包括芳香族、半芳香族、和脂肪族聚酰胺)；聚碳酸酯；聚甲醛；聚酰亚胺；聚苯并咪唑；聚酮；聚醚醚酮；聚醚酮；聚醚砜；聚(苯醚)；苯氧基树脂；聚(苯硫)；聚苯乙烯；聚烯烃(例如聚乙烯、聚丙烯、乙烯/丙烯共聚物、乙烯/1-丁烯共聚物、乙烯/丙烯/非共轭二烯共聚物、乙烯/丙烯酸乙酯共聚物、乙烯/甲基丙烯酸缩水甘油酯共聚物、乙烯/醋酸乙烯酯/甲基丙烯酸缩水甘油酯共聚物、马来酸和/或马来酸酐接枝的乙烯/丙烯共聚物等等)；ABS；弹性体(例如聚酯聚醚弹性体、聚酯聚酯弹性体等)；等。
该聚合物树脂可以是包括附加组分例如增强剂和填料的组合物的形式的。该聚合物树脂优选是含有玻璃纤维的组合物的形式的。该组合物可以任选进一步含有附加的组分如一种或多种抗氧化剂、颜料、染料、热稳定剂、UV光稳定剂、耐候稳定剂、脱模剂、润滑剂、成核剂、增塑剂、抗静电剂、阻燃剂、其他聚合物等等。附加的组分可根据物体的希望的性质进行选择。
用于相对不透明的制品的组合物可以任选进一步含有染料和/或颜料例如对于该组合物吸收激光有帮助的炭黑和苯胺黑。
用于相对透明的物体的组合物可以具有天然的颜色或可以含有对用于激光焊接的光的波长足够透明的染料。这样的染料可以包括，例如基于蒽醌的染料。
该组合物是熔融混合的混合物形式的，其中聚合物组分彼此良好的分散并且全部的非聚合物成分分散在聚合物母体中并且被聚合物母体所结合(bound)，使得该混合物形成统一整体。该混合物可以通过使用任何熔融混合的方法将组分材料相结合来获得。组分材料可以使用熔融混合器例如单或双螺杆挤出机、掺合机、捏合机、辊筒、班伯里混炼机等等来混合，来得到树脂组合物。或者，部分的材料可以在熔融混合器中混合，然后可以加入其余的材料并进一步熔融混合。如本领域技术人员能够理解的，本发明的组合物制造中的混合顺序可以是这样，即单个组分可以在一个冲程中熔融，或者填料和/或其他组分可以从侧供料器中供给，等等。
用于本发明激光焊接方法的物体可以，使用任何本领域技术人员所知方法，由聚合物树脂形成，所述方法例如喷射模塑法、挤出、吹塑、注坯吹塑、压缩模塑法、发泡模塑法、真空模塑法、旋转模塑法、压延模塑法、溶液浇铸法等。
本发明的激光焊接方法优选使用的激光器是发射具有大约800纳米到大约1200纳米波长范围的光的任何激光器。优选激光器类型的例子是YAG和二极管激光器。优选波长是近红外例如808、940、980纳米等等。
聚合物薄膜可以，使用任何适当的方法，放置在相对不透明和相对透明的物体的接合面之间。例如，薄膜可以使用胶粘剂使之附着于相对不透明和相对透明的物体之一或二者。该薄膜也可以通过重叠模塑(overmolding)粘附于相对不透明或相对透明的物体。或者，聚合物薄膜可以插在相对不透明和相对透明的物体之间，得到的层合物可以在没有任何附加固定的情况下被焊接，或者该层合物可以通过使用例如夹子、气压、或其它的合适方法被固定和紧紧地保持在一起。
在焊接期间，聚合物薄膜被熔融并且连接到被熔融的物体。
激光焊接方法在附图中进行了举例说明。图1(a-1)说明了相对透明的物体102。图1(a-2)说明了聚合物薄膜105。图1(a-3)说明了相对不透明的物体104。参考图1(b)，具有半重叠部分106的相对透明的物体102被置于与聚合物薄膜105的一面接触，并且具有半重叠部分106的相对不透明的物体104被置于与聚合物薄膜105的另一面接触而形成半重叠部分106与聚合物薄膜105之间的接合点进而形成层合结构124。层合结构124的物体102和104和聚合物薄膜102优选使用例如，夹子、气压、或其它合适的方法(未显示)被固定和紧紧地保持在一起。
参考图2和3(a)，激光光线114(由激光器(未示出)通过光纤110经由激光辐照体108而供给)在方向112穿过相对透明的物体102的碰撞面116。该光穿过相对透明的物体102和聚合物薄膜105并且辐照相对不透明的物体104的半重叠部分106的表面，导致物体104表面上的聚合物在发热点118被熔融从而使物体102和104被焊接。
图3(b)显示在区域122被激光焊接的制品120。
激光辐照体108的运动，当其扫描穿过碰撞面116时，可以通过工业机器人的手臂(未显示)控制，信息例如编排好的扫描路径已经被输入工业机器人中。或者，物体102和104和薄膜105可以附着到XYZ工作台并且相对于静止的激光辐射体移动。也可以使用任何将待焊接的物体和激光相对彼此移动的任何适当的替换方式。扫描的速度可以根据待焊接的材料而不同。例如，对于聚烯烃树脂例如聚丙烯，可以使用大约200到大约1000厘米/秒的扫描速度。另外，进行有效焊接所必需的激光能量还可以根据待焊接的材料而变化。因素包括相对透明的物体在激光波长下的透射率、物体在待焊接点处的厚度、激光的扫描速度等等。例如，对于像聚丙烯的聚烯烃树脂来说，大约10到180W的激光能量可以被使用。
当要被焊接的物体和焊接制品对燃烧敏感时，本发明的方法是特别有效的，例如当使用具有高输出能量的激光和/或当相对不透明的物体具有特别低的激光辐射透射率时。
在本发明方法中，使用的激光的输出能量优选大于大约95W并且更优选大约95到大约180W，或者更更优选大约95到大约130W。
焊接路径可以如同图1(b)所示那样是线性的，或者可以具有不同的、非线性或者部分非线性的形式。要焊接的物体可以采取多种形式和形状，例如盘状、圆柱、半球和不规则的形状。物体的碰撞面也可以沿着焊接路径具有均一的厚度或者厚度可以不同。
要焊接的物体和聚合物薄膜可以在它们的接合面具有任何适当的形式，前提是它们可以置于与聚合物薄膜适当物理接触，以便进行激光焊接。
尽管相对透明的物体在要激光焊接点处的厚度没有特别限制，只要焊接是可行的话，该部件在该点的厚度优选大约0.1到大约10毫米，或者更优选大约0.5到大约5毫米。使用具有这样厚度的物体可以使得到的焊接强度最佳化。尽管不特别限制相对不透明的物体在要激光焊接点处的厚度，只要焊接是可行的话，该部件在该点处的厚度将优选大约0.1到大约10毫米，或者更优选大约0.5到大约5毫米。
本发明还包括由本发明的方法制造的任何的激光焊接制品。有用的制品包括用于电气和电子应用的制品、汽车组件(automotivecomponent)、办公设备部件、建材、工业设备例如传送带的部件、医疗装置的部件和生活消费品例如玩具和体育用品的部件。汽车组件的例子包括发动机机舱组件、进气歧管、前舱部件(underhood parts)、散热器组件(radiator component)、仪表盘组件(cockpit instrument panelcomponent)。有用的电气和电子组件包括传感器外壳、个人电脑、液晶放映机、移动计算装置、移动电话等等。办公设备部件的例子是打印机、复印机、传真机等等的部件。
实施例
实施例1
参考图1(a-1)，530 NC010，含有30wt％玻璃纤维的聚(对苯二甲酸乙二醇酯)树脂(由E.I.duPont de Nemours and Co.，Wilmington，DE提供)，使用Sumitomo Heavy Machinery Industries，Ltd.SE100D注塑机，被注模成相对透明的物体102。该树脂熔融温度是290℃并且模具温度是120℃。
参考图1(a-3)，Rynite 530 BK503，含有30wt％玻璃纤维和黑色着色剂的聚(对苯二甲酸乙二醇酯)(由E.I.duPont de Nemours and Co.，Wilmington，DE提供)，使用与用于物体102同样的方法，被注模成相对不透明的物体104。
物体102和104具有20毫米的长度和18毫米的宽度，物体102和104在它们最厚部分的厚度是3毫米并且在半重叠部分106的厚度是1.5毫米。
参考图1(a-2)，从一片由Mitsubishi Chemical Polyester Film Inc.Co.提供的Diafoil R-310 16微米2-轴延伸聚(对苯二甲酸乙二醇酯)薄膜剪下具有厚度16微米、长度20毫米并且宽度18毫米的薄膜被用作聚合物薄膜105。该聚合物薄膜具有在940纳米0％的吸收率。该吸收百分率是通过从100％减去透射百分率和反射百分率计算的。该透射率和反射率是使用由Shimadzu Corp提供的UV3100 UV-VIS-NIR分光光度计测量的。
参考图1(b)，物体102的半重叠部分106和物体104的半重叠部分106被置于与聚合物薄膜105接触以便形成层合结构124。该层合结构124的组件被固定在0.6MPa的负载下。
参考图2，物体102和104使用德国Rofin-Sinar制造的激光器(未显示)被焊接在一起，该激光器是在940纳米波长下工作的并且具有3毫米的聚焦直径(focusing diameter)、120毫米的焦距、和500瓦的最大功率。该激光114经由光学纤维110和激光辐照体108使之从激光器被引导到物体102和104和聚合物薄膜105。该激光以1m/min的速度扫描。使用不同的激光输出能量来焊接样品。碰撞在物体102表面上的实际激光能量被测量并且在本文中称作“激光输出能量”。
所得的焊接的拉伸剪切强度(在本文中称作焊接强度)是通过将得到的焊接制品的肩部夹在由Shimadzu Corp.制造的拉伸强度试验仪中、并且在该焊接制品的纵向施加拉伸力来测定的。该试验仪在2mm/min的速率下进行操作。结果示于表1和图4中。
比较例1
使用和实施例1所用的相同的步骤进行比较例1，区别在于不使用聚合物薄膜。结果被示于表1和图4。当用96和103的激光输出能量进行焊接时发生了样品的燃烧。
表1
实施例1与对比例2的比较显示，通过将聚合物薄膜层压在两个要被激光焊接的制品之间允许这些物体在高激光输出功率下以良好的焊接强度被焊接。此外，聚合物薄膜的存在抑制了当使用在高输出能量下工作的激光焊接时物体将燃烧的可能性。

Claims (11)

1、一种用激光辐射将第一聚合物物体焊接到第二聚合物物体的方法，其中第一聚合物物体对于该激光辐射是相对透明的并且第二物体对于该激光辐射是相对不透明的，第一和第二物体每个具有接合面，所述第一物体具有相对于其所述接合面的碰撞面，所述方法包括如下步骤：(1)将第一物体的接合面与聚合物薄膜的一面物理接触，并且第二物体的接合面与聚合物薄膜的另一面物理接触，形成在第一物体、第二物体和聚合物薄膜之间的接合点；以及(2)用所述激光辐射辐照所述第一和第二物体和聚合物薄膜使所述激光辐射碰撞该碰撞面，穿过所述第一物体和聚合物薄膜并且辐照所述第二物体的所述接合面，致使所述第一和第二物体在接合面的接合点处被焊接，其中该聚合物薄膜在该激光辐射波长下具有5％或更小的吸收率。
2、如权利要求1所述的方法，其中聚合物薄膜具有小于大约100微米的厚度。
3、如权利要求1所述的方法，其中聚合物薄膜具有大约1到大约50微米的厚度。
4、如权利要求1所述的方法，其中聚合物薄膜具有大约3到大约20微米的厚度。
5、如权利要求1所述的方法，其中聚合物薄膜具有大约5到大约18微米的厚度。
6、如权利要求1所述的方法，其中聚合物薄膜包括聚酯、聚碳酸酯、聚酰胺、聚苯乙烯、和聚(甲基)丙烯酸酯中的一种或多种。
7、如权利要求6所述的方法，其中聚酯是聚(对苯二甲酸乙二醇酯)(PET)、聚(对苯二甲酸丙二醇酯)(PTT)、聚(对苯二甲酸丁二醇酯)(PBT)、聚(萘二甲酸乙二醇酯)(PEN)、和聚(1，4-环己烷二甲醇对苯二甲酸酯)(PCT)中的一种或多种。
8、如权利要求1所述的方法，其中聚合物薄膜具有小于或等于大约3％的吸收率。
9、如权利要求1所述的方法，其中聚合物薄膜具有小于或等于大约1％的吸收率。
10、一种通过权利要求1所述的方法制造的激光焊接制品。
11、权利要求10的制品，其是汽车组件形式的。
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