CN101370641B - 超声焊接方法和结构模块、特别是机动车辆门模块 - Google Patents

超声焊接方法和结构模块、特别是机动车辆门模块 Download PDF

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CN101370641B
CN101370641B CN2007800028908A CN200780002890A CN101370641B CN 101370641 B CN101370641 B CN 101370641B CN 2007800028908 A CN2007800028908 A CN 2007800028908A CN 200780002890 A CN200780002890 A CN 200780002890A CN 101370641 B CN101370641 B CN 101370641B
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projection
groove
welded
motor vehicle
connect
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CN101370641A (zh
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何塞路易斯·佩雷斯曼都威劳
瑞弗·普拉西德瑞波特
华金马丁·佩雷斯
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Faurecia Innenraum Systeme GmbH
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    • 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
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/60—Riveting or staking
    • B29C65/606—Riveting or staking the rivets being integral with one of the parts to be joined, i.e. staking
    • B29C65/607—Riveting or staking the rivets being integral with one of the parts to be joined, i.e. staking the integral rivets being hollow
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    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • B29C66/8141—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 surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81427—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 surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
    • B29C66/81429—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 surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth comprising a single tooth
    • 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
    • B29C66/8141—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 surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81431—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 surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single cavity, e.g. a groove
    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60J—WINDOWS, WINDSCREENS, NON-FIXED ROOFS, DOORS, OR SIMILAR DEVICES FOR VEHICLES; REMOVABLE EXTERNAL PROTECTIVE COVERINGS SPECIALLY ADAPTED FOR VEHICLES
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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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    • B29C66/00—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
    • B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract

本发明涉及一种在第一构件(100)和第二构件(108)之间进行超声焊接的方法，其中，第一构件具有凹槽(102)，用于收容第二构件的第一突起(112)和第二突起(114)；该方法包括以下步骤：定位第一构件和第二构件，使得第一突起和第二突起凸伸进入凹槽之内并且接触凹槽的底板(104、104′)，传递超声振动，以便在第一构件和第二构件之间产生相对运动，底板被压向第一突起和第二突起，使得第一突起(112)沿第一方向变形，而第二突起(114)沿与第一方向相反的方向变形，并至少在第一突起和底板之间形成第一焊接连接(130、104)，而在第二突起和底板之间形成第二焊接连接(132、104)。

Description

超声焊接方法和结构模块、特别是机动车辆门模块
技术领域
本发明涉及一种超声焊接方法以及结构模块，该结构模块包括互相焊接到彼此之上的构件(Bauteil)，本发明特别涉及一种机动车辆门模块。
背景技术
从现有技术的描述中可以获知不同的超声焊接方法。通常，由超声波发生器所产生的电振荡被转换为相同频率的机械振动，并通过焊接工具即所谓的超声焊极(Sonotrode)传递到工件上。通过超声波的作用，被焊接的部件在其接合表面处塑化，并通过施加的压力彼此焊接在一起。例如，由ABS、PMMA、PC、PS和SAM制成的塑胶部件可以彼此焊接在一起。同样，可以通过超声焊接在塑胶和其它材料如金属之间形成焊接连接。
从现有技术的描述中可以获知超声焊接的不同超声焊极形式，例如，DE 20 2005 003 067 U1、DE 299 23 223 U1、DE 298 23 967 U1、DE 298 13 964 U1、DE 203 14 781 U1、DE 200 02 555 U1以及DE 198 54013 C2。
同样可通过超声焊接来生产防水组件。例如，DE 199 34 596 A1公开了一种具有防水构造的连接器，该防水构造通过超声焊接制造，而DE 103 49 240 A1公开了一种铠装电缆的水密封布置，其同样为超声波焊接的。
发明内容
因此，本发明的目的是提供一种改进的构件超声焊接方法、以及包括有彼此焊接在一起的构件的结构模块，特别是一种机动车辆门模块。
本发明的目的可通过各独立权利要求中所记载的技术特征分别予以实现。从属权利要求中则给出优选的实施方式。
在根据本发明的超声焊接第一构件和第二构件的方法中，第一构件具有容纳第二构件的第一和第二突起(Vorspruenge)的凹槽(Einbuchtung)。为了使第一构件和第二构件进行超声焊接，其首先按照第一突起和第二突起凸伸进入凹槽内并接触凹槽底板的方式设置。然后，超声振动传递到构件上，从而在构件之间产生相对运动。在这期间，底板被压向第一突起和第二突起，使得突起按照相反的方向变形。这样，在突起和底板之间产生了相应的焊接连接。
在这种情况下，特别有利的是，所得到的焊接连接可按照防水的方式形成。这特别适于在突起侧面的相对较大的表面上形成每个焊接连接的情况。
按照本发明的一实施方式，凹槽基本上形成为偏方三八面体(trapezstumpffoermig)的形状。
按照本发明的一实施方式，凹槽深度大约在7mm到25mm之间，特别是大约15mm，并且具有大约从4mm到32mm范围内的开口，特别是大约8mm到16mm。凹槽的壁厚，可在大约1mm和6mm之间，特别是大约3mm。
按照本发明的一实施方式，在焊接之前，两个突起基本上彼此平行。特别地，两个突起可垂直于第二构件。
按照本发明的一实施方式，两个突起每个具有大约1mm到6mm的壁厚，特别是大约3mm。
按照本发明的一实施方式，两个突起之间的距离大约为凹槽开口的0.5到0.95倍。
按照本发明的一实施方式，两个突起具有大约相同的长度。
按照本发明的一实施方式，超声振动通过超声焊极被传递到第一构件。例如，超声焊极具有焊极尖端，其界定超声焊极的工作表面，该焊极尖端设置于底板的背面并位于两个突起之间。在超声焊极的位置，超声振动被传递，同时超声焊接被加压压向底板的背面。
按照本发明的一实施方式，上述工作表面可以为波浪形的，且两个半波是从焊极尖端处开始的。
按照本发明的一实施方式，当突起在凹槽中定位之后，且当超声焊接的焊极尖端置于底板的背面上之后，凹槽和突起以及超声焊接的工作表面对称布置。
按照本发明的一实施方式，第一或第二构件是承载板(Traegerplatte)，在其上不同的部件通过超声焊接相连接。例如，承载板可以是机动车辆门模块的载体。
另一方面，本发明提供了一种结构模块，其具有彼此焊接在一起的至少第一构件和第二构件。第一构件具有半波形弧段，其与第二构件的对应突起一起形成焊接连接。例如，在突起之侧面的相对较大的表面上形成焊接连接。
按照本发明的一实施方式，焊接连接是防水的。
按照本发明的一实施方式，结构模块是门模块，特别是机动车辆门模块。有关机动车辆门模块的描述，可从现有技术中获知，特别是那些具有在机动车辆门上定义出湿区域和干区域的载体的机动车辆门模块，例如可参考EP 0 944 497和EP 0 961 703。
对于将构件连接到载体和/或将载体定位在门内部，会产生维持干区域和湿区域之间分离的密封问题。在现有技术中，橡胶密封条/带被用来作为密封，而这会导致费力的装配。另外，随着时间的推移，橡胶密封带可能产生众多的孔隙，因此造成渗水。对此，借助本发明的防水超声焊接，使得将构件连接到载体上和/或将载体连接到门内部的成为可能。
例如，通过超声焊接，门模块的不同部件可连接到载体上，例如，电子部件特别是电连接器、窗升降部件、扬声器部件、操作部件特别是开关部件等等。
这样，就可能以高成本效率的方式生产机动车辆门模块，而同时门模块的长期密封性能得以改进，因为通过超声焊接完成的连接，与通过密封剂完成的密封相反，其性能不受制于时效。
下面，结合附图，来详细地描述本发明的具体实施方式。
附图说明
图1是在焊接方法之前、两个将要焊接在一起的构件的剖视图；
图2是图1的构件在焊接后的视图；
图3是机动车辆门模块的俯视的示意图。
上述附图中，各附图标记的含义为：
100    构件
102    槽
104    底板
104′  底板
106    开口
108    构件
112    突起
114    突起
116    超声焊极
118    工作区
120    焊极尖端
122    区域
124    区域
126    中心轴线
128    超声振动
130    侧面
132    侧面
134    侧面
136    侧面
138    侧面区域
140    侧面区域
142    门内板
具体实施方式
图1显示了具有凹槽102的构件100。在此处的实施例中，凹槽102为大概的偏方三八面体的形状。然而，凹槽102也可以采用其它的形状，如矩形、正方形、或其它几何形状。
在凹槽102的偏方三八面体中，形成底板104。底板104的深度T为几毫米，例如在7mm和25mm之间，特别是大约15mm。
凹槽102上形成具有几毫米宽度W的开口106，特别是在4mm和32mm之间，例如在大约8mm和16mm之间。宽度W和深度T之间的侧向比率(Seitenverhaeltnis)优选地位于0.5和2之间的范围。
在凹槽的范围内、尤其在其侧肋138和140的范围内，壁厚S可以在1mm和6mm之间，特别是大约3mm。
在其凹槽102区域，构件100可由热塑性塑胶构成，例如由ABS或其它塑胶构成。
构件108具有大约相同长度的两个突起112和114。突起112和114基本上彼此平行并且具有相同的长度，该长度略大于深度T。突起的壁厚可基本上在与S大小的相同数量级范围。
突起112和114之间具有距离A；该距离A可大约为凹槽106的开口的宽度W的0.5到1.0倍。例如，构件108的突起112、114由热塑性塑胶组成，如ABS或其它塑胶；突起112和114各自具有侧面130、134以及132、136，其部分区域与凹槽102特别是与其侧肋138、140以及其底板104形成进行焊接的连接区域，如图2所示。
对于构件100和108的超声焊接，采用超声焊极116，其工作区118如图1所示。工作区具有焊极尖端120，从该焊极尖端120处开始，有两个大约半波形的区域122和124。
对于构件100和108的超声焊接，首先将这些构件彼此如此放置，使得构件108的突起112和114凸伸进入到凹槽102中，从而使其接触凹槽102的底板104。
接着，安放超声焊极116，使其焊极尖端120在底板104的背面上并大约位于底板104的中心。
例如，构件100和108如此设置，使得超声焊极116的焊极尖端120大约位于底板104背面的中心，从而相对于中心轴线126大约为对称布置。
在超声焊极116的焊极尖端120设置之后，使超声焊极116传递超声振动128，从而引起相对运动、特别是在底板104和突起112以及114之间的相对运动。由此而导致焊接连接的形成。
这些焊接连接如图2所示。突起112的侧面130焊接到底板104上和/或其侧面134焊接到侧肋138上。同样的，突起114的侧面132焊接到底板104上和/或其侧面136焊接到侧肋140上。
同样如图2所示，底板104在超声焊接时发生变形，使其能够适应超声焊极116的工作区118的形状。在超声焊接过程中，通过超声焊极116对底板104的向下挤压，突起112和114进一步被分别弯曲到左边或右边，使得其侧面130、132以及侧面134、136分别套入底板104和侧肋138或140之间，从而在底板104和突起122、114之间形成相应的焊接连接。
在超声焊接中，侧肋138和140同样对应于超声焊极的工作区118而变形，并分别套入突起112和114的外部侧面134和136，使其在此也形成焊接连接。
在切断超声振动128后，按照本实施例，继续将超声焊极116于底板104上加压几秒钟，直到焊接连接变硬，这是有利的。
图3表示了构件100的实施方式，其作为机动车辆门模块的承载板。例如，构件100在机动车辆门的内部将湿区域与干区域分隔。
图3表示了构件100沿干区域方向的湿区域示意性俯视图，这意味着在图3的上部、构件100的前侧，代表了湿区域的界限，而构件100的背面定义了干区域。
在构件100背面的干区域中，可布置一个或多个构件108，其中作为一个示例，在图3中用虚线表示构件108。例如，构件108可以是电子部件特别是电连接器、窗升降部件、开关部件、扬声器部件等等。
构件108可以与构件100的凹槽相焊接，也就是，特别是与底板100和104′相焊接，如图1和图2所示。
另外，构件100也可包括一个或多个凹槽，其可成形为类似于图1和图2中的凹槽102，从而形成如图1和图2所示类型的超声焊接连接，例如，具有门内板142，从而将构件连接到门的内部。

Claims (27)

1.一种对第一构件（100）和第二构件（108）进行超声焊接的方法，其中，所述的第一构件具有凹槽(102)，用于收容所述第二构件的第一突起（112）和第二突起(114)；该方法包括以下步骤：
-   如此定位所述第一构件和第二构件，使得所述第一突起和第二突起凸伸进入所述凹槽之内、并接触所述凹槽的底板(104、104')；
-   传递超声振动，使得在所述第一构件和第二构件之间产生相对运动，其中，所述底板被压向所述第一突起和第二突起，使得所述第一突起(112)沿第一方向变形，而所述第二突起(114)沿与第一方向相反的方向变形，并且至少在所述第一突起和所述底板之间形成第一焊接连接(130、104)，而在所述第二突起和所述底板之间形成第二焊接连接(132、104)；
其中，所述超声振动是借助超声焊极(116)传递到所述第一构件；所述超声焊极包括具有焊极尖端(120)的工作区(118)，并且其中所述超声焊极的焊极尖端设置在所述凹槽的底板(104、104')的背面上、且位于所述第一突起和第二突起之间。
2.如权利要求1所述的方法，其中，所述的凹槽为偏方三八面体。
3.如权利要求1或2所述的方法，其中，所述凹槽的深度在7 mm到25 mm之间。
4.如权利要求3所述的方法，其中，所述凹槽的深度为15 mm。
5.如权利要求1或2所述的方法，其中，所述凹槽的开口的宽度在4 mm到32 mm之间。
6.如权利要求5所述的方法，其中，所述凹槽的开口的宽度在8 mm到16 mm之间。
7.如权利要求1或2所述的方法，其中，所述凹槽的壁厚在1 mm到6 mm之间。
8.如权利要求7所述的方法，其中，所述凹槽的壁厚为3 mm。
9.如权利要求1或2所述的方法，其中，在传递所述超声振动之前，所述第一突起和第二突起基本上是彼此平行的。
10.如权利要求1或2所述的方法，其中，在传递所述超声振动之前，所述第一突起和第二突起基本上是以垂直于所述第二构件进行设置的。
11.如权利要求1或2所述的方法，其中，所述突起的壁厚在1 mm到6 mm之间。
12.如权利要求11所述的方法，其中，所述突起的壁厚为3 mm。
13.如权利要求1或2所述的方法，其中，所述第一突起和第二突起具有基本上相同的长度。
14.如权利要求1或2所述的方法，其中，在所述定位之后，所述凹槽以及所述第一突起和第二突起是对称布置的。
15.如权利要求1所述的方法，其中，在所述超声焊极的工作表面，形成两个基本上半波形的区域(122、124)，该两个半波形的区域起始于所述焊极尖端(120)。
16.如权利要求1所述的方法，其中，所述超声焊极的工作表面是对称的。
17.如权利要求1或2所述的方法，其中，所述的第一构件是承载板。
18.如权利要求1或2所述的方法，其中，所述的第二构件是承载板。
19.如权利要求1或2所述的方法，其中，在所述第一突起和所述凹槽的第一侧肋(138)之间形成第三焊接连接(134、138)，而在所述第二突起和所述凹槽的第二侧肋(140)之间形成第四焊接连接(136、140)。
20.一种根据权利要求1-19之一所述方法生产的、具有第一构件和第二构件的机动车辆结构模块(100、108)，其中，所述第一构件具有第一和第二波形弧段(104)，其与所述第二构件相应的第一突起和第二突起(112、114)共同形成至少第一和第二焊接连接。
21.如权利要求20所述的机动车辆结构模块，其中，所述的焊接连接是防水的。
22.如权利要求20或21所述的机动车辆结构模块，其中，所述构件中至少一个是完全地或部分地由塑胶构成。
23.如权利要求20或21所述的机动车辆结构模块，其中，所述的机动车辆结构模块是机动车辆的门模块。
24.如权利要求20或21所述的机动车辆结构模块，其中，所述构件之一是用于机动车辆门模块的载体。
25.如权利要求20或21所述的机动车辆结构模块，其中，所述构件之一是门模块的部件。
26.如权利要求20或21所述的机动车辆结构模块，其中，所述构件之一是电连接器、窗升降部件、扬声器部件或开关部件。
27.如权利要求20或21所述的机动车辆结构模块，其中，在所述每个突起的两个侧面上与所述第一构件形成焊接连接(138、134；130、104；132、104；136、140)。
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