CN101412816A - 焊接由高温下稳定的聚合物材料制成的两个不透明元件的方法 - Google Patents

焊接由高温下稳定的聚合物材料制成的两个不透明元件的方法 Download PDF

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Publication number
CN101412816A
CN101412816A CNA2008101785085A CN200810178508A CN101412816A CN 101412816 A CN101412816 A CN 101412816A CN A2008101785085 A CNA2008101785085 A CN A2008101785085A CN 200810178508 A CN200810178508 A CN 200810178508A CN 101412816 A CN101412816 A CN 101412816A
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polymer materials
pigment
respect
laser radiation
transparent
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Inventor
J-P·阿巴
M·里克布尔格
M·马德尔塞迪莱斯
A·索泰洛米格
P·皮尼奥莱
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Alstom Transport SA
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Alstom Transport SA
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Publication of CN101412816A publication Critical patent/CN101412816A/zh
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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
    • B29C65/02—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
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    • 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
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/733—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 optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明涉及一种用于焊接由高温下稳定的聚合物材料制成的两个不透明元件的方法，该方法包括下述步骤：制备由高温下稳定的不透明的聚合物材料制成的下部元件(2)，并且以下述方式为其添加碳粉：该下部元件(2)能够吸收激光辐射(1)；制备由高温下稳定的聚合物材料制成的上部元件(4)；利用穿过该上部元件(4)并且在该上部元件(4)和该下部元件(2)之间的界面上实现焊接的激光辐射(1)激光焊接该下部元件(2)和该上部元件(4)。通过向聚合物材料中添加颜料，在其制备期间，该上部元件(4)被制作成相对于可见光辐射是不透明的和相对于激光辐射是透明的，该颜料是不改变聚合物材料性质的矿物类颜料或有机类颜料，相对于激光辐射是透明的并且具有高温稳定性。

Description

焊接由高温下稳定的聚合物材料制成的两个不透明元件的方法
技术领域
本发明涉及一种用于焊接两个由高温下稳定的聚合物材料制成的不透明元件的方法，该方法包括下述步骤：
-制备由高温下稳定的聚合物材料制成的下部元件，并且以下述方式为其添加碳粉：该下部元件相对于可见光辐射是不透明的并且能够吸收激光辐射；
-制备由高温下稳定的聚合物材料制成的上部元件；
-利用穿过该上部元件并且在该上部元件和该下部元件的界面实现焊接的激光辐射激光焊接该下部元件和该上部元件。
本发明还涉及由高温下稳定的热塑性材料制成的元件的组件和包括这种组件的整流器(power converter)的封装设备或外壳(casing)。
背景技术
在已知的整流器中，整流器的封装设备或外壳包括多个由聚合物材料制成的元件的组件，这些组件利用形成粘性和紧密接合的材料，例如硅酮组装在一起。举例来说，这些元件被组装在一起形成保护盖，在该盖的厚度中包括有用于冷却能量转换器的管道。该整流器可以耐受基本高于250℃的温度，但不允许任何热漂移(thermal drift)。因而，该管道具有热交换流体或冷却液体，例如流经它们的水和二醇的混合物。
但是为了确保外壳元件之间的长期完全紧密接合，由于其物理和化学特性的缘故，用粘接剂接合是不能令人满意的。因此，导致冷却液体泄漏并可能引起整流器短路的问题。
为了克服这些缺点，理想的解决方法就是将这些聚合物材料的元件彼此焊接起来。因而，由于焊接这些元件会导致在组装区中材料连成一体并因此与被组装元件具有相同的物理和化学特性的聚合物材料接合处，这些元件之间的组装区将会完全紧密。
但是，激光焊接由高温下稳定的聚合物材料制成的两个不透明元件会出现问题：这是因为必需确保激光辐射穿过元件之一并在这两个元件之间的界面上实现焊接，且不会改变聚合物材料的电、机械和化学特性。
文献WO-2006/085643公开了一种用于焊接两个聚合物材料元件的方法，该元件之一被制作成相对于可见光辐射和激光辐射是不透明的，而另一个则通过添加蒽醌类着色剂(colorant)被制作成相对于可见光辐射是不透明的而相对于激光辐射是透明的。这种着色剂允许工业聚合物的焊接，这些聚合物具有低于着色剂降解温度的熔点和工作温度，其中所述降解温度是从250℃开始出现的。这种焊接方法不适于工作温度非常高，特别是300℃以上的聚合物的焊接。
发明内容
本发明的目的之一是通过提出下述方法来克服上述问题，该方法用于焊接两个不透明的元件，其中在两个元件之间的界面执行所述焊接，并且不会改变元件材料的特性。
为此，本发明涉及上述类型的方法，其中通过向聚合物材料中添加颜料(pigment)，在其制备期间，上部元件被制作成相对于可见光辐射是不透明的和相对于激光辐射是透明的，该颜料是不改变聚合物材料性质的矿物类颜料或有机类颜料，相对于激光辐射是透明的并且具有高温稳定性。
根据本方法的其它特征：
-在激光焊接期间上部元件和下部元件彼此压靠；
-下部元件和上部元件的聚合物材料以及添加到上部元件中的颜料在至少250℃的温度下是稳定的；
-下部元件和上部元件的聚合物材料属于下述族，该族包括：
-聚醚酰亚胺；
-诸如聚砜、聚醚砜及其它衍生物之类的具有砜键的热塑性塑料；
-聚醚醚酮；
-亚苯基聚硫化物；
-聚碳酸酯；
-通过混合上述成分或使上述成分发生共同反应得到的配制物；
-该颜料是钴和铝的氧化物(Al2O3，CoO)或单独的钴氧化物(CoO)或磷酸钴(Co3(PO4)2)或锰紫；
-激光源在组装两个元件的组装区上方移动以便通过该激光源发射出的激光辐射在该组装区上通过，并且
-混合到制作下部元件的聚合物中的碳粉是微米级碳粉(micrometriccarbon powder)。
本发明还涉及一种由高温下稳定的热塑性材料制成的元件的组件，其包括多个聚合物材料元件，这些聚合物材料元件相对于可见光辐射是不透明的并且具有高温稳定性，其中至少一个元件包括添加到聚合物材料中的颜料，该颜料是不改变聚合物材料性质的矿物类颜料或有机类颜料，相对于激光辐射是透明的并且具有高温稳定性。
根据该组件的其它特征：
-元件之间的组装区是紧密的；
-该组件的是电绝缘的；并且
-通过由上面所定义的焊接方法将元件组装在一起。
本发明还涉及包括至少一个如上所述的组件的整流器的外壳。
本发明还涉及相对于可见光辐射是不透明的并且具有高温稳定性的聚合物材料，其包括添加到该聚合物材料的颜料，该颜料是不改变聚合物材料性质的矿物类颜料或有机类颜料，相对于激光辐射是透明的并且具有高温稳定性，所以该聚合物材料相对于激光辐射是透明的。
本发明还涉及如上所述的聚合物材料在如上所述的焊接方法中的应用。
附图说明
通过参照附图阅读下面的说明，本发明的其它方面和优点将会更易于理解，在下面的说明中给出了例子，在附图中示意性地说明了激光焊接两元件的步骤。
请参看唯一的附图，其描述了利用由激光源(未示出)发射出的激光辐射1将下部元件2激光焊接到上部元件4。
具体实施方式
下部元件2和上部元件4由相同的具有高温稳定性的热塑性聚合物材料制成。这些材料属于这样的组：例如，聚醚酰亚胺；诸如聚砜或聚醚砜及它们的衍生物之类的具有砜键的热塑性塑料；聚醚醚酮(PEEK)或亚苯基聚硫化物(PPS)；或具有高性能的，特别是非晶的任何其它热塑性材料。
通过将微米级碳粉混合到聚合物材料中，将下部元件2制成相对于激光辐射和可见光辐射是不透明的。术语“相对于激光辐射和可见光辐射是不透明的”想要表达的意思是：可见光辐射或激光辐射都不能穿过下部元件2。下部元件2包括，例如，按体积0.6％的微米级碳粉(具有直径在2至15μm之间的颗粒)与聚合物混合。所述碳粉吸收激光辐射1，当下部元件2受到该激光辐射1照射时，该激光辐射1具有加热和熔化下部元件2的表面6的效果。
利用矿物颜料将上部元件4制成相对于可见光是不透明的。该颜料具有这样的特征：其相对于激光辐射1是准透明的，也就是说它仅仅非常轻微地吸收激光辐射，并且相对于可见光是不透明的。此外，该添加物不会改变上部元件4的聚合物材料的性质，特别是其机械、化学和电性能。不会因为该添加物改变的机械性能之一是，例如，聚合物材料的杨氏模量。不会因为该添加物改变的电性能是，例如，聚合物材料的击穿电压和中断电场(interruption field)。不会因为该添加物改变的化学性能之一是，例如，聚合物材料的化学惰性，也就是说，其与其它材料的相容性。上述性质都仅经由非限制性的例子给出。
颜料在非常高的温度下，例如超过800℃，特别是超过1000℃也是稳定的，并且因此能够与类似于PEEK之类的工作温度非常高的聚合物一起被使用。这种矿物颜料例如是，钴和铝的氧化物(A l2O3，CoO)尖晶石或单独的钴氧化物(CoO)或磷酸钴(Co3(PO4)2)或锰紫。上部元件4包括，例如，按体积0.14％的钴和铝的氧化物(Al2O3，CoO)类的颜料。
下部元件2和上部元件4的聚合物材料和上部元件4的颜料在至少250℃的温度下是稳定的。
为了执行焊接，在组装区8将上部元件4放置在下部元件2的表面6上。
激光辐射1由上部元件4之上的激光源发射出。由于颜料相对于激光辐射1是透明的，激光辐射穿过上部元件4到达在组装区8中的下部元件2的表面6。由于下部元件2中的碳粉的存在，激光辐射1被吸收到表面6区域中，并导致下部元件2的材料熔化，从而在上部元件4和下部元件2之间的界面实现焊接。
在焊接操作期间下部元件2和上部元件4彼此压靠，如图中的箭头10所示。
激光源还以下述方式可移动：使激光辐射1在组装区8上通过，并且在整个区域上都实现焊接，如图中的箭头12所示。
元件2和4可以是任意形状。元件相对于彼此的定位利用简易的几何，例如，用于基本是平面的元件的三维图表表示。对于复杂几何形状，利用光导纤维提供激光辐射，所述光导纤维能够使激光辐射1在组装区8上精确定位。
激光源是，例如，发射在可见光谱区或在近红外线区域，优选具有波长基本等于808nm的连续发射二极管。激光辐射的单次通过以通过速率基本在0.1mm.s-1和1mm.s-1之间，优选基本等于0.5mm.s-1足以实现焊接。激光束是均匀的并且是基本矩形的形状，该矩形具有基本在4至5cm之间的宽度和基本在0.5mm至5mm之间的长度。激光的功率基本在100W至500W之间，优选基本等于350W。激光二级管可以被供给基本在10A至50A之间的电流，优选在20A至30A之间，这授予它基本在0.8W.mm-1和1.6W.mm-1之间的功率密度。
因此上述方法能够实现相对于可见光不透明的两个元件的焊接，而不会改变元件聚合物材料的电、机械和化学特性。特别是，它使得在两个于非常高的温度下稳定的元件之间实现焊接成为可能。但是，该方法可用于任何类型的聚合物材料，并且特别是具有较低熔化温度的工业聚合物(technical polymer)。因此，与用于焊接任意类型的聚合物材料的着色剂相比，颜料的添加代表了更“普遍”的解决方案。由于着色剂有限的热稳定性，着色剂的使用限定了能够焊接的聚合物材料的种类。使用着色剂仅能够将具有较低熔化温度的工业聚合物焊接在一起，而使用颜料另外允许工作温度非常高的聚合物的焊接。
此外，在元件由连续相同的材料彼此连接在一起的情况下所产生的焊缝是完全紧密的，并且该焊缝具有与下部元件2和上部元件4相同的性质。通过使用PTFE(未示出)的横向装边(lateral rim)，可以大大改善焊接连接的整体质量，该横向装边与待焊接的元件的周边形状相一致。那个外模板则防止任何塑料材料的流出。其也可以防止焊缝中气泡的形成，气泡会损害电操作(部分放电)。
上述方法在由具有高温稳定性的聚合物材料制成的元件的结构组件中具有特殊的用途，特别是整流器的外壳。这种外壳包括至少一个由多个元件形成的组件，所述多个元件根据上述方法被组装在一起。
这些整流器排出大量的热，而该方法允许外壳的结构耐受这种可能达到至少250℃的温度。
被组装的元件允许具有流过例如由水和二醇形成的冷却液体的冷却通道的结构。焊接的密封性允许形成该通道，而不会有泄漏和因此形成短路的危险。
此外，由于组装的元件和焊缝的电性能，所述外壳是电绝缘体。
由具有高温稳定性的聚合物材料制成的元件的组件也可以应用到其它领域，例如汽车工业，航空工业，微电子工业等等。

Claims (14)

1、一种用于焊接由聚合物材料制成的两个元件(2，4)的方法，所述元件相对于可见光辐射是不透明的并且具有高温稳定性，该方法包括下述步骤：
-制备由高温下稳定的聚合物材料制成的下部元件(2)，并且以下述方式为其添加碳粉：该下部元件(2)相对于可见光辐射是不透明的并且能够吸收激光辐射(1)，
-制备由高温下稳定的聚合物材料制成的上部元件(4)，
-利用穿过上部元件(4)并且在该上部元件(4)和该下部元件(2)之间的界面上实现焊接的激光辐射(1)激光焊接该下部元件(2)和该上部元件(4)，
其特征在于，通过向聚合物材料中添加颜料，在其制备期间，该上部元件(4)被制作成相对于可见光辐射是不透明的和相对于激光辐射是透明的，该颜料是不改变聚合物材料性质的矿物类颜料或有机类颜料，相对于激光辐射是透明的并且具有高温稳定性。
2、如权利要求1所述的焊接方法，其特征在于，在激光焊接期间该上部元件(4)和该下部元件(2)彼此压靠。
3、如权利要求1或2所述的焊接方法，其特征在于，该下部元件(2)和该上部元件(4)的聚合物材料以及添加到该上部元件(4)中的颜料在至少250℃的温度下是稳定的。
4、如权利要求1至3中任一项所述的焊接方法，其特征在于，该下部元件(2)和该上部元件(4)的聚合物材料属于下述族，该族包括：
-聚醚酰亚胺；
-诸如聚砜、聚醚砜及其它衍生物之类的具有砜键的热塑性塑料；
-聚醚醚酮；
-亚苯基聚硫化物；
-聚碳酸酯；
-通过混合上述成分或使上述成分共同发生反应得到的配制物。
5、如权利要求1至4中任一项所述的焊接方法，其特征在于，该颜料是钴和铝的氧化物(Al2O3，CoO)或单独的钴氧化物(CoO)或磷酸钴(Co3(PO4)2)或锰紫。
6、如权利要求1至5中任一项所述的焊接方法，其特征在于，激光源在组装两个元件(2，4)的组装区(8)上方移动以便通过该激光源发射出的激光辐射(1)在该组装区(8)上通过。
7、如权利要求1至6中任一项所述的焊接方法，其特征在于，混合到制作该下部元件(2)的聚合物中的碳粉是微米级碳粉。
8、一种由高温下稳定的热塑性材料制成的元件的组件，其包括多个聚合物材料元件(2，4)，所述元件相对于可见光辐射是不透明的并且具有高温稳定性，其特征在于，至少一个元件(4)包括添加到聚合物材料中的颜料，该颜料是不改变聚合物材料性质的矿物类颜料或有机类颜料，相对于激光辐射是透明的并且具有高温稳定性。
9、如权利要求8所述的组件，其特征在于，所述元件(2，4)之间的组装区(8)是紧密的。
10、如权利要求8或9所述的组件，其特征在于，该组件是电绝缘的。
11、如权利要求8至10中任一项所述的组件，其特征在于，通过根据权利要求1-7中任一项所述的焊接方法将所述元件(2，4)组装在一起。
12、一种整流器的外壳，其特征在于，它包括至少一个根据权利要求8至11中任一项所述的组件。
13、一种相对于可见光辐射是不透明的并且具有高温稳定性的聚合物材料，其特征在于，它包括添加到该聚合物材料的颜料，该颜料是不改变聚合物材料性质的矿物类颜料或有机类颜料，相对于激光辐射是透明的并且具有高温稳定性，所以该聚合物材料相对于激光辐射是透明的。
14、一种如权利要求13所述的聚合物材料在根据权利要求1至7中任一项所述的焊接方法中的应用。
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