CN101415536B - 用于连接成形塑料体的激光透射焊接方法 - Google Patents

用于连接成形塑料体的激光透射焊接方法 Download PDF

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Publication number
CN101415536B
CN101415536B CN2007800119358A CN200780011935A CN101415536B CN 101415536 B CN101415536 B CN 101415536B CN 2007800119358 A CN2007800119358 A CN 2007800119358A CN 200780011935 A CN200780011935 A CN 200780011935A CN 101415536 B CN101415536 B CN 101415536B
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China
Prior art keywords
pipe fitting
laser
tubular body
layer
absorbing material
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CN2007800119358A
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CN101415536A (zh
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托马·克赖舍
弗朗茨·库格尔曼
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Fresenius Medical Care Deutschland GmbH
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Fresenius Medical Care Deutschland GmbH
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Priority to CN201210225319.5A priority Critical patent/CN102765194B/zh
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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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/52—Joining tubular articles, bars or profiled elements
    • B29C66/522—Joining tubular articles
    • B29C66/5221—Joining tubular articles for forming coaxial connections, i.e. the tubular articles to be joined forming a zero angle relative to each other
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
    • A61M39/00—Tubes, tube connectors, tube couplings, valves, access sites or the like, specially adapted for medical use
    • A61M39/10—Tube connectors; Tube couplings
    • A61M39/14—Tube connectors; Tube couplings for connecting tubes having sealed ends
    • A61M39/146—Tube connectors; Tube couplings for connecting tubes having sealed ends by cutting and 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
    • B29C65/1635—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
    • B29C65/1635—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
    • B29C65/1641—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 making use of a reflector on the opposite side, e.g. a polished mandrel or a mirror
    • 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
    • B29C65/1667—Laser beams characterised by the way of heating the interface making use of several radiators at the same time, i.e. simultaneous 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
    • 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
    • B29C65/1674—Laser beams characterised by the way of heating the interface making use of laser diodes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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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    • 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
    • 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
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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
    • B29C66/01—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
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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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/534—Joining single elements to open ends of tubular or hollow articles or to the ends of bars
    • B29C66/5344—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially annular, i.e. of finite length, e.g. joining flanges to tube ends
    • 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
    • B29C66/712—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 the composition of one of the parts to be joined being different from the composition of the other part
    • 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
    • B29C66/72—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 structure of the material of the parts to be joined
    • B29C66/723—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 structure of the material of the parts to be joined being multi-layered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • 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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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明涉及用于将管件连接到管状体的设备，还涉及用于将管件连接到管状体的焊接方法，其中所述管件的管壁由彼此不同的至少两个材料层构成，这些层中的一层至少部分地含有吸收激光辐射的物质，包括下列步骤：提供无PVC的管件和管状体，将所述无PVC管件与所述管状体彼此有效插入，使得所述管件和所述管状体的表面区域重叠，使用规定波长的激光辐射照射所述管件与所述管状体的所述重叠表面区域，其中，在该激光焊接方法中，不必移动所述连接件或该设备的零件。

Description

用于连接成形塑料体的激光透射焊接方法
本发明涉及一种激光透射焊接方法，尤其是将塑料制管部件焊接成大致管状体的激光透射焊接方法，例如，其它管部件、连接器、设备、搭扣等。
原则上，正确连接塑料制成形体，尤其是不同塑料制成形体存在各种可能性。例如，两个成形体可通过粘合剂粘接或焊接方法彼此连接。
对于焊接方法，除了IR焊接(例如，参见WO 2005/080067)之外，近来集中检验了通过激光辐射的焊接。
借助于激光的焊接方法的基本物理原理要求至少一部分施加的激光被要彼此连接的两个成形部分的至少之一的材料吸收，至少吸收至使得其可转换为热量的程度，并且使得被激光加热的点的材料通过加热变成流体，使其能够连接到第二成形部分的塑料材料上。
限制焊接方法的参数为使用的激光的波长和塑料在该波长的吸收性能。特别地，在这种情形下，在可见光范围(400-750纳米)内或红外范围内使用具有610-840纳米波长的高能二极管激光和具有约1050纳米波长的Nd：YAG固态激光。但是，常常还可使用具有约11000纳米波长的CO2气体激光。
塑料的吸收特性极大地依赖于所用激光辐射的波长，从而其加工也极大地依赖于所用激光辐射的波长。塑料的不均匀性(例如色素、填充料或加强材料)以及在局部结晶塑料情形下的结晶结构分散了输入的辐射，尤其是减小了进入塑料的辐射渗透深度。
当激光束照在要加热的塑料件上时，激光辐射会反射、吸收和透射不同的程度。按照所谓的Bouguer法律，根据深度描述渗透进塑料的辐射强度降低。在这种情形下，输入强度随着材料深度呈指数形降低。
由于塑料辐射热产生的热分解，特别会出现问题，尤其是通过CO2激光时。塑料部件的表面温度通常快速升高，这与塑料的弱导热性相关，其中存在热材料分解的风险。[例如，在H.Potente等人的“Laserschweiβen von Thermoplasten”(Plastverarbeiter 1995，No.9，page 42 ff.)、F.Becker等人的“Trends beiSerienschweiβverfahren in Kunststoffe 87”(1997，page 11 ff.)和H.Puetz等人在Modern Plastics(1997，page 121 ff.)中公开了激光焊接方法的原理]。
例如，通过混合吸收剂，可控制在一定波长对激光是透明的聚合物或塑料的吸收性能，从而可控制其透射。例如，这种吸收剂可为碳黑，也可为近年来发展的特种染料。
具有这种可控吸收性能的一系列染料可在商业上获得，其特别发展为混合在聚合混合物中，以便在规定的波长能够激光焊接。为此，还可使用I.A.Jones等人在“Use of infrared dyes for Transmission Laser Welding of Plastics”(Tech2000 Conference Proceedings，page 1166 ff.)中公开的染料。
与其它焊接方法相比，一种特殊形式的激光焊接方法，即激光透射焊接方法具有可快速和有效焊接几何形状更加复杂的连接表面的优点。在将管件焊接到如连接器、安装件等上的情形下，必须始终通过激光束照射一个连接件，即，为了激光辐射不被吸收。第二连接件或第二连接件的部分必须能够吸收产生热量的激光。通常从连接件的外面实施照射。
例如，EP 1552916 A1描述了通过激光焊接方法连接管状体，但是，其中为了可以不连接的方式焊接两个三维部件，激光必须绕着管状体的连接部位旋转，这需要复杂的设备和机构。
US 2003/0141634描述了医用激光焊接管，其中，在具有多层结构的管中，每层都包括激光吸收材料。这里，同样，每个管或者整个激光透射设备都必须进行旋转运动，以便可在管的整个圆周上将其彼此焊接。
DE 10245355 A1描述了通过套筒连接管元件。在所述的激光透射方法中，管部分、所谓的连接器和套筒彼此焊接。这样，同样，其焊接必需持续绕着整个圆周的激光束，这只能通过旋转激光装置或要焊接的管来实施。
WO 2005/063469公开了可通过所谓套筒彼此连接的管件。管与套筒之间的连接通过含有在700至2500nm为吸收剂的材料的连接材料实施。这样，激光焊接操作必需激光或要焊接的管的旋转运动。
因此，从现有技术获知的激光焊接方法是有缺陷的，特别是必须始终通过激光照射要连接在一起的两个成形件之间的连接表面时。这要求要彼此连接的表面可从所有的侧面易于接近。通常，某些部件的几何形状不允许全向照射。通常，由于其几何形状，无法实施各自部件的旋转，结果，在许多情形下，迄今无法进行激光焊接。
因而，本发明的目的是一种克服现有技术上述缺陷的激光透射焊接方法，特别是能够使要彼此连接的两个成形件进行完全的全向焊接而无需旋转。本发明的另一目的是提供一种设备，通过该设备可快速地焊接要彼此连接的两个成形件，而无需旋转该设备的零件或要焊接的零件。
根据本发明，其目的通过用于焊接包括管件和管状体的两个连接件的设备来实现，所述设备包括激光和镜子，所述激光、所述连接件和所述镜子可布置成使得所述激光的光束照射在所述连接件上，然后照射在所述镜子上，其中，所述镜子部分地具有中空圆筒的内表面的轮廓。通过该设备的帮助，可更加均匀地照射含有所述吸收物质的层。不会出现管的局部区域的过热，焊缝变得更加均匀。
在优选实施例中，所述激光的光束在光束部分发散，并且所述发散光束部分首先照射在所述管件上，然后照射在镜子上。该实施例的优点在于对含有吸收物质的层的照射更加均匀。
通常，通过激光束照射要连接的连接件，连接件为管件或管状体。另一方面，在焊接期间，由于散射和反射效应，提供的激光能量损失了大部分。所有未垂直入射在管表面上的光线都会偏转，超过一定的极限角，光束会经历全反射，在连接件的焊接中不起作用。另外，要渗透的材料的激光吸收层远大于边缘区域，因此其应用于下方区域的能量较少。通过光束在镜子上的反射，利用了由于反射或透射的能量，否则将损失掉。在镜子上反射的光束可重新照在管材料上，如此可用于焊接操作。
镜子的轮廓描述了中空圆筒的内表面部分。不在全圆柱形轮廓一侧的孔用作入射激光束的入孔。中空圆筒的理想轮廓可有微小的变化。所以中空圆筒的横截面可以不是圆形的，而是椭圆的。
在本发明的范围内，如果激光束横截面沿着光束方向变大，那么激光束是发散的。在使用所述设备进行焊接操作的情形下，该布置的优势在于，管件包括吸收物质的层的所有区域都可被均匀地照射。从而保证了包含吸收物质的层之间的温度差小。
所述镜子优选由铝或铝合金构成。已经发现，特别地，由抛光铝制成的镜子具有最佳的反射特性。由钢制成的镜子会发热至非常高的程度，并有微小的反射。由黄铜制成的镜子同样会发热，也反射一部分辐射。随着镜子表面由于热量逐渐变钝，反射效果降低。但是，表面通过抛光可恢复良好的反射。
所述中空圆筒的直径优选在5与25mm之间，更优选为20mm。所述镜子表面与所述连接件表面之间的距离不应当过大，以使反射在镜子上的光能不会辐射大部分，并不渗透过所述连接件。另外，优选地，具有达13mm的总直径的管子可通过该设备焊接。具有更大直径的管子通常具有更大的壁厚度。特别地，不含吸收物质的层更厚。该层具有更大的热吸收能量。通过该更大的热吸收，从焊接处理去除了热量，结果可出现焊缝缺陷。管子尺寸和镜子表面与连接件表面之间的距离为与中空圆筒直径相关的限制因素。
优选地，在根据本发明的设备中，使用具有从750至1000nm波长、优选为808nm波长的二极管激光。所述激光具有从380至520W的功率，优选具有500W的功率。通过所述二极管激光，能够产生可会聚和发散的激光束。在该情形下，所述激光称为“散开式二极管阵列激光”。另外，所述激光的功率和由所述激光发生的光的波长对于焊接处理是最佳的，使得没有焊缝缺陷，并且聚合物材料不会变得过热。
本发明基于的目的还可通过提供使用激光和镜子将无PVC管件连接到管状体(“连接件”)的激光焊接方法来实现，其中所述管件的管壁用于通过激光和镜子将无PVC的管件连接到管状体的激光焊接方法，其中所述管件的管壁由彼此不同的至少两个材料层构成，这些层中的一层至少部分地含有吸收激光辐射的物质，其中在该方法中：
a)提供所述无PVC管件和所述管状体，
b)将所述无PVC管件与所述管状体彼此有效插入，使得所述管件和所述管状体的表面区域重叠，
c)将所述管件和所述管状体的所述重叠表面区域布置在所述镜子前，所述镜子部分地具有中空圆筒的内表面的轮廓，
d)使用激光辐射照射所述管件与所述管状体的所述重叠表面区域，使得从所述管件或管状体反射或透射的激光束被所述镜子反射，并再次部分地照射在所述管件或所述管状体上，在所述管件与所述管状体之间实现焊接连接。
与必须移动要焊接的零件或设备零件的焊接方法相比，通过该方法，可显著缩短照射时间。在所述连接件通过反射和透射辐射的激光在所述镜子上反射，并可再次用于其它焊接操作，使得无需移动所述激光和/或所述连接件。因此，将照射时间缩短至几秒。优选地，可在短于3秒内将所述连接件彼此焊接。因此，在使用该方法的情形下，在步骤d)中实施照射不超过3秒。
为了获得最佳的结果，并形成均匀的焊接束，在该方法中使用具有中空圆筒内表面的轮廓的镜子。更优选地，使用根据本发明的设备执行该方法。
在该方法的优选实施例中，当激光束照在所述管部分上时，其直径小于要焊接的管部分的直径。所述激光束的直径与所述管部分的直径相比优选在1比2和1比5之间。
由于其辐射借助于所述镜子均匀地照射在整个表面上，所以根据本发明的方法省却了所有的行进路线。当光束照射在管部分上时，如果光束部分的直径小于管部分的直径，那么也省却了所有的行进路线。
根据本发明的方法的另一优点在于实现更加均匀的焊接。被认为是第二有智效果的是，由于连接件可更加容易地插入安装件和从其拆除，所以获得了激光光学器件与焊点之间的空间。
如果使用的镜子具有中空圆筒内表面的轮廓，那么镜子与管壁之间的距离大致始终相等。如果所述设备的镜子并不严格地遵循中空圆筒的轮廓，那么镜子与管壁之间的距离可不等。如果中空圆筒的横截面为椭圆，那么要连接的连接件以同心的方式布置在所述镜子的前面。
本发明基于的目的还可通过提供将无PVC管件连接到管状体(“连接件”)的激光透射焊接方法来实现，其中所述管件的管壁用于通过激光和镜子将无PVC的管件连接到管状体的激光焊接方法，其中所述管件的管壁由彼此不同的至少两个材料层构成，这些层中的一层至少部分地含有吸收激光辐射的物质，其中在该方法中：
a)优选地提供所述无PVC管件和所述管状体；
b)将所述无PVC管件与所述管状体彼此有效插入，使得所述管件和所述管状体的表面区域重叠；
c)使用规定波长的激光辐射照射所述重叠表面区域的基本为半圆柱形的第一部分；
d)通过含有吸收物质的所述层的吸收，所述激光辐射削弱至初始能量的90-50％，在所述第一部分实现焊接连接；
e)为在第二部分中实现焊接连接，所述削弱的激光辐射照射在重叠表面区域的基本为半圆柱形的所述第二部分上，第二部分面对一个辐射源，并与第一部分基本上呈镜面对称关系。
根据本发明的两种方法无论是否使用镜子，都提供了只从一侧照射两个连接件的优点，其中全向获得所述连接件的有效焊接连接。结果，无需转动所述激光设备或所述连接件就可实施根据本发明的方法，使得与现有方法相比，实施根据本发明的方法的机械设备远没有那么复杂，因此实现了极大的简化。
如果不使用镜子而实施该方法，那么激光或连接件必须经过一个滑动过程，以产生均匀的焊缝。使用根据本发明的设备的方法的优势在于，可对所述连接件进行更加均匀的照射，并且无需移动设备的零件或者要焊接的零件。
在包括步骤a)至e)的该方法中，还可使用用于将激光反射到连接件上的镜子。如果使用镜子，那么该方法还包括将削弱的激光辐射放射在镜子上、反射激光束和将激光束重新照在所述管件上的步骤。
为了执行根据本发明的方法，对本发明所必要的在于，提供具有多层结构的管件，其中必须在层中含有吸收激光辐射的物质。
在本文中，术语“有效”理解为意味着所述管件与所述管状体以无缝或无隙的方式彼此重叠。在该情形下，优选地，所述管件在所述管状体上作用接触压力。
术语“管件”理解为意味着流体可通过的任意长度的管的任意部分。由于可预见医用管，例如在血液透析系统中，但因为近年来的研究PVC(聚氯乙烯)中使用的可塑剂会溶解于通过管子的生物流体，会在人体组织中引起健康危害，所以所述管必须特别是无PVC的设计。
在含有吸收物质的层中，对于所用的激光，特别是通过吸收物质的量，确定焊接连接的可焊性或稳定性。根据本发明，所述管的外表面(即，其内侧或外侧)包括功能薄层(即，含有吸收物质)。该层通常与位于其下方的第二层共同挤压在一起。含有吸收物质的层的层厚度在从20至100μm的范围内，使得它们通过共同挤压仍可制成较薄的层厚度。
含有吸收物质的层可作为构成所述管内部的表面，或者在本发明的不同实施例中作为构成所述管外部的表面，特别地，可给与要彼此焊接的成形件各种几何形状布置：例如，在本发明的优选实施例中，所述管可插在所述管状体(例如，连接器)中，使得在该情形下，外层必须具有吸收物质的功能，即，该层能与要焊接的第二连接件(连接器)接触。
在本发明的另一优选实施例中，所述功能层(即，含有吸收物质的层)构成了所述管件的内侧，使得管状体可插在所述管中。
在本发明的优选实施例中，所述层只有与要焊接的管状体重叠区域的部分含有吸收物质。在上述两个可选几何形状中这是显然的。特别地，从而能够使用昂贵的染料用于吸收。
含有吸收物质的层中的吸收物质浓度通常在50与300ppm之间，优选80-200ppm，选择成使得沿着激光渗透路线的长度被第一大致半圆柱形部分的吸收物质层吸收所用激光的约10-50％，优选15-40％，从而可用于第一部分的焊接。应当理解，在该连接中，本领域的技术人员将吸收物质的类型和数量匹配成所使用的激光的类型或其波长，以获得上述值。
优选地，可根据本发明使用的管件的层由无PVC材料构成，特别地，含有吸收物质的层包括聚烯烃，例如聚乙烯、聚丙烯、聚异戊二烯，还有苯乙烯-乙烯嵌段共聚物，例如苯乙烯-乙烯-丁二烯-苯乙烯嵌段共聚物(SEBS)、苯乙烯-乙烯-丙烯-苯乙烯嵌段共聚物(SEPS)、苯乙烯-异戊二烯-苯乙烯共聚物(SIS)、苯乙烯-乙烯-丁二烯共取物(SEB))及其混合物。
其它至少一个无吸收物质的层具有给予所述管件一定机械稳定性(抗弯性等)的功能。
为此，纯聚烯烃材料特别优选作为该层的材料，特别地，例如聚丙烯、聚乙烯、聚异戊二烯及其混合物。在另一优选实施例中，显然，还可使用苯乙烯-乙烯-丁二烯-苯乙烯嵌段共聚物(SEBS)、苯乙烯-乙烯-丙烯-苯乙烯嵌段共聚物(SEPS)、苯乙烯-异戊二烯-苯乙烯共聚物(SIS)、苯乙烯-乙烯-丁二烯共取物(SEB)及其混合物等，或与纯聚烯烃一起使用。
在本发明另一实施例中，根据本发明所用的管件具有最大8mm的内径和最大12mm的外径。优选地，所述管件的壁厚度为2mm，在另一具体实施例中，例如，在使用所述管作为所谓血液系统导管的情形下，其壁厚度甚至为1.5mm。
在另一优选实施例中，所述管可包括层的其它可选次序。其重要性只在于，这些层并不削弱激光焊接处理，使得这些层必须对激光基本是透明的。
因此，特别是有关机械稳定性、抗弯性、弹性等方面，可充分考虑更加复杂的需求。
优选地，在根据本发明的方法内使用所谓二极管激光。该二极管激光具有达1000nm的波长，优选750至900nm，最优选为808nm。在实施根据本发明的方法中尤其重要的是，通过施加或不施加压力获得连接平面，两个连接件在该连接平面优选以无缝的方式彼此重叠，使得通过被激光加热的流体聚合物特别容易地保持其有效连接，从而根据本发明，在焊缝几何形状的设计中可获得大量的多样性。在通过激光尤其是通过二极管激光连接塑料中最常用的几何形状为搭接缝，这也在本案中通过参考而使用。
在该连接中，其重要性在于，在本发明范围内可预计可能的激光类型的多样性(例如，如果不使用镜子实施该方法，那么可使用Nd：YAG激光，或者无论是否使用镜子，可使用根据本发明方法的二极管激光，等等)，从而还具有不同的波长，由于激光辐射的大能量强度，关于吸收物质没有任何的限制。因为大的能量强度，不必在相应所选吸收物质的吸收中最大限度地照射。如果在最大相应物质周围约±100nm的窗口内实施照射，那么它就足够了，使得在使用根据本发明的方法中可利用宽范围的吸收物质。通常，在包括步骤a)至e)的方法中，使用发射尽可能平行的光束的激光。
在根据本发明的不使用镜子反射激光束的方法中，特别优选地，激光辐射沿着激光透射路线长度被第一基本半圆柱形部分的含吸收物质的层由于吸收物质而削弱约10-50％，优选15-40％。这些范围使得即使在所述管的个别圆段的更长透射路线上也能使足够的激光辐射仍可达到泵管的相对圆段，使得在其可保证牢固的焊接。
如果不使用镜子来使用本方法，那么在采用二极管激光的情形下，激光功率通常约为400W。应当理解，这些值仅仅是给本领域技术人员在选择适当激光时的参考。同样，在该方法中，使用的激光可为具有约400W功率的“散开式二级管阵列激光”，其将辐射集中在约10mm直径的点上。激光辐射作用的时间周期通常为1-10s，优选为2-8s，特别优选为3-7s，依赖于所述管的厚度。在具有约12mm直径的血液泵管的情形下，实现牢固焊接连接的典型时间周期为7秒，在具有6.5mm直径的管的情形下，约3秒。
本发明的目的还通过管件与管状体之间的激光焊接连接获得，其中无论是否使用镜子，都可通过根据本发明的方法产生连接。无需使用特别大的机械复杂性就可产生激光焊接连接，特别是在医用领域中，尤其是在输送生理性流体、输注液或血液的情形下。
这样，对于要连接的管件和连接件具有特别的需求，使得相应聚合物质选择必须依从有关从上述现有技术已知的可见波长范围的透明度、热消毒能力和生物适应性。因此，本发明同样包括在管件与管状体(例如，连接器或另一管件)之间具有这种激光焊接连接的多样性的管系统，例如，用于使用在血液透析回路中。
下面参考附图中的具体实施例更加全面地解释本发明，但是其并不应理解为对本发明概念的限制。
示出了：
图1为通过了连接的截面图，其中连接器被推到管件上；
图2为连接器被推入管中的连接；
图3为连接器与插在连接器内的管之间的激光焊接连接；
图4为包括激光和中空圆柱形镜子的装置。
图1示出了聚丙烯制连接器101与管之间的根据本发明的组合100，其中所述管包括内层103和外层102，外层102含有激光吸收材料，例如染料。在这种情形下，外层102具有约50μm的厚度。吸收物质可使用如BASF公司的Lumogen IR 788，但是在本发明的范围内，可使用在所使二极管激光波长范围内吸收的任何其它吸收物。在将管件推入连接器101之后，施加3-5秒的具有波长808nm的激光辐射104。在由大写字母“A”标识的半圆柱形区域内，激光辐射104被外层102内的吸收物质吸收，熔化了塑料，使得在外层102聚丙烯连接器101与管之间产生有效连接。如上面详细描述的，辐射104被吸收，并照射在第二半圆件B上，由箭头105表示，被削弱了约10-50％，这里，其同样被外层102中的吸收物质吸收，从而也通过熔化管件的层102与聚丙烯连接器101之间的层102而产生有效连接。其余的辐射通常并不完全吸收。附图还示出了不同的线路长度，激光的波阵面必须沿着这些线路传递：这样，线路长度11远小于线路长度12，使得激光沿着线路长度11的削弱(即，大致位于削弱10％的范围内)小于沿着线路12的削弱(吸收大致在50％)。
图2示出了可在根据本发明的方法范围内使用的连接200的另一实施例。在该情形下，由例如聚丙烯制成的连接器201插入管件中，使得管202的内表面含有激光吸收材料，外层203用于稳定目的。
应当清楚理解，在层202与200的之间或外侧可布置另一层，这些层对于激光是透明的，如上所述。层202的厚度同样是50μm，同样使用BASF的Lumogen IR 788作为吸收物质。
现在，同样使用波长λ＝808nm的激光辐射(由箭头204表示)照射装置200，辐射在第一半圆或半圆柱件A中吸收约10-50％，使得在连接器201与辐射吸收层202之间产生有效连接。未吸收的辐射205照射在半圆柱件B 202内的层202上，这里它同样产生吸收、加热和熔化，使得在管件的整个圆周上实现完全焊接到连接器。
因此，如这里所述，通过根据本发明的方法，激光或者要连接的连接件100至200的旋转对于实现全向焊缝并非必需的。
图3示出了聚丙烯制连接器301与管件306之间的连接300，其中管件306包括不带激光吸收材料的内层307和在与连接器301内侧重叠的部分303含有激光吸收物质的外层302。如图1和2中所述，随着激光辐射304的动作，产生有效全向焊缝305。
图4示出了用于焊接管件的设备400，该设备包括激光402和镜子404。二极管阵列发射光束403，光束403在第一部分会聚，在平面C内具有最小的截面，然后发散。发散光束部分在平面D内照射在管件401上。然后发散和透射的激光束照射在镜子404上，在这里被反射，再次部分地照射在管件上。通过该装置，确保了对含有吸收物质的层的均匀照射，使得管件被均匀地焊接。
实施例1
在优选实施例中，使用具有下列结构的无PVC管：
内径  8mm
外径  12mm
壁厚  2mm
管的含有吸收物质的层具有如下成分：
吸收物质的厚度50μm
层：
成分：60％SEBS Tuftec 1221(Asahi)
      40％PP-R RD204CF(Borealis)
100ppm Lumogen IR 788BASF
无吸收物质的层包括70％的SEBS Tuftec 1221(Asahi)与30％的SIS(Hybrar7125F，Kuraray)的混合物。
通过共同挤压产生具有两个层的管件。
所谓连接器由聚丙烯制成，用作第二连接件。在实施例中，将管件以图3中所述的方式推入聚丙烯连接器中，其区别为整个外层含有吸收物质。
彼此插入的连接件为管件和连接器，根据本发明，通过由Laserline，D-Mühlheim公司制造的具有808nm的二极管激光(二极管激光LDF 1000-500)从一侧照射。使用所述的透射焊接，覆盖在根据本发明的方法的范围内。根据本发明，从而实现了有效全向焊缝，无需转动一个或两个连接件。
这样实现的焊接连接满足了医疗领域中遇到的关于密封强度、抗张强度和热杀菌能力的所有需求。抗张强度(“管裂强度”)根据DIN 53455确定，约为170N。在本案中，甚至在该力作用下，管破裂，而焊接的连接并不松脱。通常，根据本发明焊接的连接的抗张强度的下限为120N，依赖于焊接的区域，最大为160-170N，其中如上所述，由于各管的破裂不同，无法准确地确定上限的精确测量。

Claims (19)

1.用于通过激光和镜子将无PVC的管件连接到管状体的激光焊接方法，其中所述管件的管壁由彼此不同的至少两个材料层构成，这些层中的一层至少部分地含有吸收激光辐射的物质，其中在该方法中：
a)提供所述无PVC管件和所述管状体；
b)将所述无PVC管件与所述管状体彼此有效插入，使得所述管件和所述管状体的表面区域重叠；
c)将所述管件和所述管状体的所述重叠表面区域布置在所述镜子前，所述镜子部分地具有中空圆筒的内表面的轮廓；
d)使用激光辐射照射所述管件与所述管状体的所述重叠表面区域，使得从所述管件或管状体反射或透射的激光束被所述镜子反射，并再次部分地照射在所述管件或所述管状体上，在所述管件与所述管状体之间实现焊接连接。
2.如权利要求1所述的方法，其中，所述镜子具有中空圆筒的内表面的轮廓。
3.如权利要求1所述的方法，其特征在于，不含有所述吸收物质的层的材料从聚乙烯、聚丙烯、聚异戊二烯、苯乙烯-乙烯-丁二烯-苯乙烯嵌段共聚物(SEBS)、苯乙烯-乙烯-丙烯-苯乙烯嵌段共聚物(SEPS)、苯乙烯-异戊二烯-苯乙烯共聚物(SIS)、苯乙烯-乙烯-丁二烯共聚物(SEB)及其混合物中选择。
4.由根据权利要求1所述的方法在管件与管状体之间产生的激光焊接连接。
5.用于血液透析回路中、包括根据权利要求4的在管件和管状体之间的多个激光焊接连接的管系统。
6.用于将无PVC的管件连接到管状体的激光焊接方法，其中所述管件的管壁由彼此不同的至少两个材料层构成，这些层中的一层至少部分地含有吸收激光辐射的物质，其中在该方法中：
a)提供所述无PVC管件和所述管状体；
b)将所述无PVC管件与所述管状体彼此有效插入，使得所述管件和所述管状体的表面区域重叠；
c)使用规定波长的激光辐射，照射所述重叠表面区域的基本为半圆柱形的第一部分；
d)通过含有吸收物质的所述层的吸收，所述激光辐射削弱至初始能量的90-50％，在所述第一部分实现焊接连接；
e)为在第二部分中实现焊接连接，所述削弱的激光辐射照射在重叠表面区域的基本为半圆柱形的所述第二部分上，第二部分面对一个辐射源，并与第一部分基本上呈镜面对称关系。
7.如权利要求1、2或6所述的方法，其特征在于，所述吸收物质包含在构成所述管件内表面的层中。
8.如权利要求7所述的方法，其特征在于，在步骤b)中，将所述管状体推入所述管件中。
9.如权利要求1、2、或6所述的方法，其特征在于，所述吸收物质包含在构成所述管件外表面的层中。
10.如权利要求9所述的方法，其特征在于，在步骤b)中，将所述管件推入所述管状体中。
11.如权利要求1或6所述的方法，其特征在于，含在所述吸收物质包含层内的所述吸收物质的浓度为50-300ppm。
12.如权利要求11所述的方法，其特征在于，含有所述吸收物质的层包括无PVC的材料。
13.如权利要求12所述的方法，其特征在于，所述材料从聚乙烯、聚丙烯、聚异戊二烯、苯乙烯-乙烯嵌段共聚物如SEBS、SEPS、SIS、SEB及其混合物中选择。
14.如权利要求13所述的方法，其特征在于，含有所述吸收物质的层的厚度为20至100μm。
15.如权利要求10所述的方法，其特征在于，所述管件具有最大4mm的厚度。
16.如权利要求1或6所述的方法，其特征在于，所述管状体为连接器或另一管件。
17.如权利要求16所述的方法，其特征在于，所述连接器由聚丙烯构成。
18.如权利要求15所述的方法，其特征在于，所述管件包括其它层。
19.如权利要求18所述的方法，其特征在于，所述其它层可透过激光辐射。
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