CN101518950A - 振动焊接方法和振动焊接设备 - Google Patents

振动焊接方法和振动焊接设备 Download PDF

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Publication number
CN101518950A
CN101518950A CNA2009101185485A CN200910118548A CN101518950A CN 101518950 A CN101518950 A CN 101518950A CN A2009101185485 A CNA2009101185485 A CN A2009101185485A CN 200910118548 A CN200910118548 A CN 200910118548A CN 101518950 A CN101518950 A CN 101518950A
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CN
China
Prior art keywords
vibration welding
guard member
resin base
vibrating member
work rest
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CNA2009101185485A
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CN101518950B (zh
Inventor
久井研司
金本周二
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Honda Motor Co Ltd
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Honda Motor Co Ltd
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Priority claimed from JP2008046043A external-priority patent/JP5046999B2/ja
Priority claimed from JP2008046044A external-priority patent/JP4990186B2/ja
Priority claimed from JP2008102683A external-priority patent/JP5226363B2/ja
Application filed by Honda Motor Co Ltd filed Critical Honda Motor Co Ltd
Publication of CN101518950A publication Critical patent/CN101518950A/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
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/301—Three-dimensional joints, i.e. the joined area being substantially non-flat
    • 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
    • B29C65/06—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding
    • B29C65/0609—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding characterised by the movement of the parts to be joined
    • B29C65/0618—Linear
    • 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
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7841—Holding or clamping means for handling purposes
    • 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
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    • 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
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • 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
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    • B29C66/05—Particular design of joint configurations
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    • B29C66/122—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
    • B29C66/1222—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a lapped joint-segment
    • 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
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    • B29C66/122—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
    • B29C66/1224—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a butt joint-segment
    • 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
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    • B29C66/126—Tenon and mortise joints
    • 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
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    • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • B29C66/1312—Single flange to flange joints, the parts to be joined being rigid
    • 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
    • B29C66/302—Particular design of joint configurations the area to be joined comprising melt initiators
    • B29C66/3022—Particular design of joint configurations the area to be joined comprising melt initiators said melt initiators being integral with at least one of the parts to be joined
    • B29C66/30223—Particular design of joint configurations the area to be joined comprising melt initiators said melt initiators being integral with at least one of the parts to be joined said melt initiators being rib-like
    • 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
    • B29C66/532—Joining single elements to the wall of tubular articles, hollow articles or bars
    • 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
    • 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
    • B29C66/61—Joining from or joining on the inside
    • 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
    • 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
    • B29C66/731—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 intensive physical properties of the material of the parts to be joined
    • B29C66/7311—Thermal properties
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    • B29C66/73116—Melting point of different melting point, i.e. the melting point of one of the parts to be joined being different from the melting point of the other part
    • 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
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • 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
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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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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • 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
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/90—Measuring or controlling the joining process
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Abstract

本发明涉及振动焊接方法和振动焊接设备。其中，可相对彼此振动的基板(20)和振动板(22)将仪表板(12)、储存箱(14)和管道(16)以成层方式夹持在其间，仪表板(12)、储存箱(14)和管道(16)利用振动在压力下彼此接合。氨基甲酸乙酯制成的保护件(24)布置在用于在其上放置基板(20)的工件架(20a)上。储存箱(14)由熔点较低的材料制成，管道(16)由熔点较高的材料制成。保护件(24)的厚度根据保护件(24)支撑树脂基底(12)、储存箱(14)或管道(16)的部位而不同。

Description

振动焊接方法和振动焊接设备
技术领域
本发明涉及振动焊接方法和振动焊接设备，用于通过夹紧、加压并利用一对相对彼此振动的振动件使树脂基底和树脂工件振动而将树脂基底和树脂工件相互焊接成层。
背景技术
至今为止，现有技术中习惯通过振动焊接将树脂部件接合到另一树脂部件。该振动焊接处理不需要粘合剂并且不用诸如加热干燥处理的后续处理。振动焊接处理有利地用于接合例如汽车的内部装饰件。由于汽车内部装饰件的外观很重要，所以理想的是防止内部装饰件由于过度振动焊接而变形，并且防止其由于振动而被擦伤。
日本特开专利公报No.2000-043567公开了一种用于振动焊接产品的支承夹具，该支承夹具具有用于吸收重叠部分的局部厚度差从而使振动夹具的压力保持恒定水平的弹性件。
为了焊接由一种树脂材料模制的部件，可根据待焊接部件的材料和形状设定适当的条件，从而实现必需的外观品质和接合强度。
日本特开专利公报No.2001-232686公开了一种振动焊接夹具，该焊接夹具在其与产品接触的表面上具有氨基甲酸乙酯树脂层，从而保持产品外观。具体地说，该公报揭示了将空调管道部件振动焊接到作为汽车内部装饰件的仪表板上。振动焊接夹具上的氨基甲酸乙酯树脂层设置为产品表面的保护件，并且具有均匀的小厚度而没有其他特殊考虑。
根据后一公报中公开的现有技术，所述管道部件被支撑在形状与管道部件互补的下夹具上，仪表板被支撑在形状与仪表板互补的上夹具上。下夹具和上夹具在它们的整个表面上分别支撑管道部件和仪表板。
支撑仪表板的表面被保护件支撑在上夹具上，并与仪表板和管道部件一起夹持在上夹具与下夹具之间。
使上夹具朝向下夹具移动，并相对于下夹具水平前后移动。仪表板和管道部件通过上夹具和下夹具受压和振动。
仪表板和管道部件的表面保持相互摩擦接触并通过摩擦热熔化。最后，使仪表板和管道部件的熔化表面固化，从而将仪表板和管道部件相互接合。
前部乘客SRS(辅助约束系统)气囊的储存箱、空调器管道等通过振动焊接接合到汽车仪表板的相反侧。储存箱和管道由于其所需规格而由不同材料制成。例如，储存箱由柔顺且熔点较低的TPO(热塑性烯烃)制成，因为其起到在气囊膨胀时打开其前侧的铰链作用，而管道由熔点较高的PP(聚丙烯)制成。
至今为止，这些不同的工件通过振动焊接在不同处理中接合到仪表板。如果在相同的压力和振动条件下在一个处理中将它们接合到仪表板，那么熔点低的材料趋于比熔点高的材料熔化更多，因此材料被不规则焊接。任一工件都容易发生机械强度水平不足。而且，至少一个工件可能熔化过深，从而趋于使仪表板的焊接有多个部件的设计前表面变形。仪表板的设计前表面的任何变形都不是优选的，因为设计表面具有满意的外观是非常重要的。
当在不同压力和不同振动条件下通过振动焊接在不同的处理中将储存箱和管道接合到仪表板时，针对相应的适当接合强度将它们熔化至相应的适当深度，仪表板的设计表面不会变形。
然而，不同的振动焊接处理耗时且效率较低，因为需要将工件加载至振动焊接设备以及从振动焊接设备卸载工件的相应处理，还需要其它的预备处理。
在相同压力和振动条件下焊接时由于具有不同的形状任一工件都会趋于变形。
仪表板具有复合曲面，包括以不同倾角保持抵靠诸如焊接夹具的支撑件的不同部位。根据现有技术，由于仪表板在振动焊接处理中在保持在均匀压力下的同时振动，所以由于不同的倾角而使仪表板沿不同于理想振动方向的方向运动。结果，仪表板未均匀焊接到其它部件。仪表板的焊接部的焊接质量可能下降，并且由于施加在振动焊接设备上的不当作用力而有可能缩短振动焊接设备的使用寿命。
为了解决以上问题，有可能提出对具有相同倾角的焊接部位利用不同的振动焊接设备。然而，利用不同的振动焊接设备不经济且效率低，因为振动焊接设备的总成本高并且涉及的制造步骤数量大。
此外，管道具有多个焊接部，在不同的处理中焊接这些部分效率低。
仪表板具有复合曲面和相当大的面积。为了在整个表面上支撑仪表板，用于支承仪表板的支承件需要为与仪表板形状互补的复合形状，所需的保护材料量较大。理想的是找到一种支撑形状复杂且面积大的树脂基底的简单方法，而且期望减少保护材料用量。
可能有效的是将间隔件插在下夹具或上夹具的多个部分中，用于支撑高熔点的工件，以防止工件被不规则焊接。然而，由于下夹具和上夹具在它们的整个表面上支撑管道和仪表板，所以必须考虑仪表板和管道的尺寸制造误差来设立间隔件的厚度，从而使间隔件能插入这些部分中。因此，需要进行多次试差法来设计间隔件。
如果将厚度过大的间隔件插入夹具部，施加在夹具部上的压力就会过高。在该夹具部中，尽管仪表板和高熔点工件的焊接强度较大，但仪表板的可视设计表面趋于变形而使外观受损。
当通过振动焊接在不同处理中使熔点不同的材料制成的部件相互接合时，制造步骤数量增加，并且完成成品需要很长时间。
发明内容
本发明的一个目的是提供一种振动焊接方法和一种振动焊接设备，用于在一个处理中将两个或更多个树脂工件同时焊接而不使它们变形。
本发明的另一目的是提供一种振动焊接方法和一种振动焊接设备，用于不管树脂基底在其相应焊接部处的倾角如何都能提高焊接品质，并用于在一个处理中同时焊接具有不同倾角的多个焊接部。
本发明的又一目的是提供一种振动焊接方法和一种振动焊接设备，用于在通过振动焊接在同一处理中接合具有不同熔点的树脂部件时使树脂材料熔化量基本均匀，从而容易地制成具有优异外观的焊接成品。
根据本发明的一个方面，提供一种振动焊接方法，该振动焊接方法用于通过在第一振动件和第二振动件之间以成层方式夹持树脂基底和树脂工件，然后使所述第一振动件和所述第二振动件相对于彼此振动，从而利用振动在压力下使所述树脂基底和树脂工件彼此焊接，该振动焊接方法包括以下步骤：使至少两个所述树脂工件保持与所述树脂基底接触，并且在所述树脂基底与所述第一振动件之间以及/或者在所述树脂工件与所述第二振动件之间设置保护件，其中所述保护件的厚度根据该保护件支撑所述树脂基底和/或所述树脂工件的部位而异。
可在一个处理中将两个以上的树脂工件同时焊接到树脂基底。树脂工件的材料可熔化至足够深，并防止了树脂工件和树脂基底变形。
与树脂基底保持接触的所述至少两个树脂工件由不同材料制成，所述保护件的厚度可根据树脂工件在被该保护件支撑的部位处的材料而异。可在一个处理中将由不同材料制成的两个以上的树脂工件同时焊接到树脂基底。树脂工件的材料可熔化至足够深，并防止了树脂工件和树脂基底变形。
如果保护件包括氨基甲酸乙酯件，那么其具有润滑能力和适当的机械强度水平及柔性水平，而且具有用于防止树脂基底被擦伤的光滑表面。由于保护件非常耐用，所以其更换和维护的频率较低，并且成本较低。
当所述树脂工件在被所述保护件支撑的部位处的熔点较低时，所述保护件的厚度可较小。熔点较低的树脂工件在较薄的保护件的作用下振动较小，而熔点较高的树脂工件在较厚的保护件的作用下振动较大。因此，树脂工件振动的程度取决于其熔点。
可基于所述树脂基底在被所述保护件支撑的部位处面对其中一个所述振动件的接触表面的倾角，设定所述保护件的厚度。
如果所述保护件的厚度根据所述树脂基底面对所述振动件的接触表面的倾角而异，那么在焊接部中所述树脂基底的倾角对于提高焊接品质的影响减小，而且可在一个处理中同时焊接具有不同倾角的焊接部。所述保护件的厚度与所述保护件所处的角度无关，其指的是在与保护件的表面正交的方向上的厚度。
所述保护件的厚度可通过相对于所述第一振动件和所述第二振动件相对彼此振动的方向的第一倾角和相对于前述方向的垂直方向的第二倾角适当限定。
所述振动焊接方法还可包括以下步骤：使所述树脂工件在至少两个部位保持与所述树脂基底接触，该树脂基底的面对所述第一振动件的接触表面的倾角在所述两个部位处不同；将所述树脂基底置于所述第一振动件上的独立工件架上，所述独立工件架取决于所述两个部位处的倾角；以及将所述保护件置于所述独立工件架中的保持与至少一个产品设计表面接触的独立工件架上。
取决于倾角的独立工件架不需要支撑所述树脂基底的整个表面，结构相对简单，并且具有较小支撑面积，这样减少了所述保护件的材料量。
至少一个所述独立工件架可不设置所述保护件。
所述振动焊接方法还可包括以下步骤：设置用于支撑所述树脂基底的预定区域的多个工件架，这些工件架从所述第一振动件的面对所述第二振动件的表面朝向所述第二振动件伸出；设置用于向所述树脂基底和所述树脂工件施加压力的多个杆，这些杆从所述第二振动件的面对所述第一振动件的表面朝向所述第一振动件伸出，其中可至少在所述第一振动件与所述工件架之间插设间隔件，并且调整所述间隔件的厚度以设定所述工件架的上端面的位置。
如果在所述第一振动件与所述工件架之间插设所述间隔件，就可调整所述间隔件的厚度以设定所述工件架的上端面的位置，从而控制施加到所述树脂基底和所述树脂工件的压力。具体地说，向插入较厚间隔件以使工件架的上端面的位置较高的区域施加较高的压力，向插入较薄间隔件以使工件架的上端面的位置较低的区域施加较低的压力。因此，在需要较高压力的部分中的材料熔化量与在需要较低压力的部分中的材料熔化量相等，从而使树脂工件的焊接程度及其焊接强度基本均匀。从而，所述树脂基底和所述树脂工件被焊接成具有良好外观的成品。
因此，将较厚的间隔件插入熔点较高的树脂工件待与树脂基底接合的区域中，将较薄的间隔件插入熔点较低的树脂工件待与树脂基底接合的区域中，使得树脂工件的熔化量基本相等。在熔点较低的树脂工件与树脂基底接合的区域中可不插入间隔件。
如果通过振动焊接将熔点相同的树脂工件分别同时接合到树脂基底的平坦和倾斜表面，那么振动件施加到树脂基底的平坦表面的压力变得高于振动件施加到树脂基底的倾斜表面的压力，因此平坦表面上的材料熔化量更大。如果通过间隔件抬高用于支撑倾斜表面的工件架，那么工件架的上端面上升而增加施加到倾斜表面的压力。这样可使材料熔化量相等。换言之，根据本发明的振动焊接方法还可应用于将熔点相同的树脂工件同时接合到树脂基底的相应的平坦和倾斜表面上的振动焊接处理。
因此，即使待焊接部分所需的压力彼此不同，也可在一个处理中接合这些部分。振动焊接方法的步骤数量未增加，获得成品所需的时间也未延长。
由于采用了仅支撑树脂基底的多个区域的多个工件架，所以与单个一体式工件架相比更容易安装和拆卸。从而非常容易将间隔件插入适当位置。此外，间隔件的厚度设定不需要考虑树脂基底和树脂工件在制造时产生的尺寸误差，从而避免了复杂的试差过程。
所述保护件可布置在所述树脂基底的产品设计表面上。这样设置的所述保护件有效地保护产品设计表面不会由于振动件的振动而被擦伤。
所述树脂基底可由聚丙烯制成，所述树脂工件可由聚丙烯和热塑性烯烃制成。
结合附图从以下描述将更加清楚本发明的以上和其它目的、特征和优点，附图中以示例性实施例的方式示出了本发明的优选实施方式。
附图说明
图1是根据本发明第一实施方式的振动焊接设备和待通过该设备接合的工件的分解立体图；
图2是根据第一实施方式的振动焊接设备以及由该设备夹持的仪表板、储存箱和管道沿图1的线II-II剖取的前剖视图；
图3是根据第一实施方式的振动焊接设备以及由该设备夹持的仪表板、储存箱和管道的侧剖视图；
图4是根据第一实施方式的振动焊接设备的剖视图，该设备使用厚度根据仪表板、储存箱和管道的被夹持部位调整的保护件；
图5是根据第一实施方式的振动焊接设备的剖视图，该设备使用长度根据仪表板、储存箱和管道的被夹持部位调整的推杆；
图6是根据第一实施方式的振动焊接设备的剖视图，该设备包括位于树脂工件上的保护件；
图7是在焊接部中测得的材料熔化量的曲线图；
图8是根据本发明第二实施方式的振动焊接设备和待通过该设备接合的工件的分解立体图；
图9是根据第二实施方式的振动焊接设备以及由该设备夹持的仪表板、储存箱和管道沿图8的线IX-IX剖取的前剖视图；
图10是根据第二实施方式的振动焊接设备以及由该设备夹持的仪表板和管道的放大局部前剖视图；
图11是根据第二实施方式的振动焊接设备以及由该设备夹持的仪表板、储存箱和管道沿图8的线XI-XI剖取的侧剖视图；
图12是表示保护件基于倾角θ1、θ2的适当厚度的曲线图；
图13是表示保护件基于倾角θ1、θ2的适当厚度的映射表；
图14是根据第二实施方式的振动焊接设备的剖视图，该设备使用长度根据仪表板、储存箱和管道的被夹持部位调整的推杆；
图15是根据第二实施方式的振动焊接设备的剖视图，该设备包括位于树脂工件上的保护件；
图16是根据本发明第三实施方式的振动焊接设备和待通过该设备接合的工件的分解立体图；
图17是根据第三实施方式的振动焊接设备以及由该设备夹持的仪表板、储存箱和管道沿图16的线XVII-XVII剖取的前剖视图；
图18是工件架的放大分解立体图；并且
图19是推杆的放大分解立体图。
具体实施方式
下面将参照附图的图1至19详细描述根据本发明优选实施方式的振动焊接方法和振动焊接设备。
首先，下面将描述根据本发明第一实施方式的振动焊接方法和振动焊接设备10a(图1)。在根据第一实施方式的振动焊接方法中，利用振动焊接设备10a通过振动焊接将前部乘客SRS气囊的储存箱(树脂工件)14和空调器管道(树脂工件)16接合到汽车的仪表板(树脂基底)12。
仪表板12由熔点约为166℃的PP(聚丙烯)制成。储存箱14由熔点约为150℃的TPO(热塑性烯烃)制成。管道16由熔点约为166℃的PP制成。储存箱14较柔顺，而管道16较硬。
管道16包括中央空气管16a、一对端部空气管16b和除霜器空气管16c，它们中限定有相应的空气通路(未示出)。因此，管道16呈中空管组件的形式。
在中央空气管16a、端部空气管16b和除霜器空气管16c各自的下端上布置待接合到仪表板12的多个焊接肋(焊接部)32a的多个焊接件(焊接部)32b。
储存箱14呈后端开口的箱形式，并具有用于储存SRS气囊的结构。储存箱14具有底板14a，底板14a包括粗网眼并且其底部作为焊接件30b接合到仪表板12的焊接肋30a。底板14a被铰接为使得当SRS气囊充气时底板14a可打开。焊接肋30a包括可在SRS气囊充气时裂开的易碎区域。
如图1所示，振动焊接设备10a包括作为第一振动件的基板20、作为第二振动件的振动板22、保护件24和控制器26。
基板20是用作振动焊接设备10a的基底的部件，可在控制器26的控制下通过多个升降器31(见图2)远离底板(未示出)升起并朝向底板下降。当基板20升起时，其朝向振动板22运动。当基板20下降时，其远离振动板22运动。基板20具有用于将作为工件的仪表板12定位并置于其上的工件架20a，储存箱14和管道16置于仪表板12上。仪表板12置于工件架20a上，使其产品设计表面12a面向下。工件架20a例如由铝制成。
振动板22布置在基板20上。振动板22具有多个向下伸出以保持焊接件30b、32b的推杆22a。当基板20朝向振动板22上升时，基板20和振动板22的推杆22a可将仪表板12的焊接肋30a和储存箱14的焊接件30b以成层方式夹持在其间并将仪表板12的焊接肋32a和管道16的焊接件32b以成层方式夹持在其间，并向这些焊接肋和焊接件施加压力。该压力可由控制器26控制。
振动板22可通过控制器26和振动装置27相对于基板20横向振动，例如沿仪表板12的纵轴线的水平方向X，从而使工件振动。从而振动板22和基板20用作相对彼此振动的一对振动件。振动板22振动的幅度和频率以及振动板22振动的时间可由控制器26控制。
保护件24安装在工件架20a上，即在基板20与仪表板12之间。
保护件24包括具有光滑表面的氨基甲酸乙酯部件，并具有润滑能力和在其上适当支撑仪表板12的适当的机械强度及柔性水平。保护件24保持与仪表板12的产品设计表面12a接触，用于保护产品设计表面12a不会由于振动而擦伤。
如图2和3所示，保护件24的厚度根据树脂工件(即储存箱14或管道16)在被保护件24支撑的部位处的材料而异。当树脂工件在被保护件24支撑的部位处的材料熔点较低时，保护件24的厚度较小。具体地说，保护件24在其支撑由熔点较低的材料(TPO)制成的储存箱14的部位处具有较小厚度Aa1，在其支撑由熔点较高的材料(PP)制成的管道16的部位处具有较大厚度Aa2。保护件24可不必呈单个保护层的形式，而是可呈多个保护层的形式，从而通过单个保护层提供较小厚度，通过多个保护层提供较大厚度。如果保护件24包括多个保护层，那么保护层可不必由一种材料制成。
保护件24的厚度还可因待焊接工件的形状而异。具体地说，在储存箱14被焊接到仪表板12的部位，仪表板12具有可在SRS气囊充气时裂开的易碎区域。由于仪表板12不应在该部位过度振动，所以保护件24在该部位的厚度较小以降低施加到仪表板12的振动。
保护件24的整个上表面光滑，以紧贴配合到仪表板12的产品设计表面12a。通过工件架20a的高度调整保护件24的厚度。
下面将描述利用这样构造的振动焊接设备10a通过振动焊接将储存箱14和管道16接合到仪表板12的振动焊接方法。
在预备处理中，将仪表板12定位并置于工件架20a上。当保护件24安装在工件架20a的上表面上时，仪表板12置于工件架20a上，保护件24插设在它们之间。
然后，将储存箱14和管道16定位并置于仪表板12上。可选的是，在将仪表板12置于工件架20a上之前，可将储存箱14和管道16定位并临时固定在仪表板12上，然后可将仪表板12置于工件架20a上。
基板20在控制器26的控制下通过升降器31提升。基板20和振动板22的推杆22a将仪表板12的焊接肋30a和储存箱14的焊接件30b以成层方式夹持在其间并将仪表板12的焊接肋32a和管道16的焊接件32b以成层方式夹持在其间，并向这些焊接肋和焊接件施加压力。因保护件24的厚度而异的压力施加至焊接肋30a和焊接件30b的接触表面以及焊接肋32a和焊接件32b的接触表面。推杆22a例如由铝制成。
然后，振动板22在控制器26的控制下通过振动装置27以给定的幅度和频率沿水平方向X横向振动。当振动板22这样振动时，焊接肋30a和焊接件30b的接触表面以及焊接肋32a和焊接件32b的接触表面产生摩擦热从而通过振动焊接接合在一起。
在振动板22振动给定时间之后，或者在焊接肋30a、32a以及焊接件30b、32b熔化给定材料量之后，振动板22停止振动。致动升降器31以降低基板20，并将已经接合在一起的仪表板12、储存箱14和管道16作为焊接产品移除。在焊接产品中，储存箱14和管道16的焊接件30b、32b充分地熔化至仪表板12中以获得足够的焊接强度水平。然而，振动焊接设备10a防止储存箱14和管道16的焊接件30b、32b熔化过深，因此仪表板12的产品设计表面12a不会变形。
振动焊接设备10a能够在一个处理中将由不同材料制成的储存箱14和管道16焊接到仪表板12。因此，通过振动焊接设备10a执行振动焊接方法非常有效。
如上所述，保护件24包括具有光滑表面的氨基甲酸乙酯部件，并具有润滑能力和适当的机械强度及柔性水平。由于保护件24保护仪表板12的产品设计表面12a，所以防止了产品设计表面12a在振动板22振动时擦伤。
在支撑管道16的中央空气管16a、端部空气管16b和除霜器空气管16c的部位处，保护件24的厚度Aa2保持相同。然而，即使保护件24的厚度Aa2在这些部位处相同，由于各种原因也不能在接触表面上产生相同的摩擦力。如图4所示，在支撑由相同材料制成的树脂工件(管道16)的部位处，保护件24可具有不同的厚度Aa2’、Aa2”。
根据上述振动焊接方法，当基板20上升时，使推杆22a与储存箱14和管道16的焊接件30b、32b的上表面同时接触，从而向焊接件30b、32b施加相同的压力。然而，即使向焊接件30b、32b施加相同的压力，由于各种原因也不能在接触表面上产生适当的摩擦力。如图5所示，推杆22a可具有不同的长度Ba、Ba’以向焊接件30b、32b施加不同的压力。在图5中，长度Ba’略小于长度Ba，使得具有较小长度Ba’的推杆22a略晚于具有较大长度Ba的推杆22a与对应焊接件32b接触。
在上述振动焊接设备10a中，仅在仪表板12上布置保护件24。根据设计条件，如图6所示，保护件24也可布置在储存箱14和管道16上。如果在储存箱14和管道16上布置有保护件24，那么可省去仪表板12上的保护件24。
图7表示在执行根据第一实施方式的振动焊接方法时，在振动焊接设备10a中测得的材料熔化量。在图7中，实线曲线50代表从储存箱14的焊接件30b和仪表板12的焊接肋30a熔化的材料量，实线曲线52代表从管道16的焊接件32b和仪表板12的焊接肋32a熔化的材料量。从曲线50、52可以看出，焊接件30b、32b和焊接肋30a、32a的材料在振动开始时刻t0之后的时刻t1熔化，并且以基本相同的速度继续熔化。在图7中，双点划线曲线54代表在对比例中保护件24具有恒定厚度时从管道16的焊接件32b和仪表板12的焊接肋32a熔化的材料量。从曲线54可以理解，管道材料在较晚时刻开始熔化，并且最终的材料熔化量较小。
如上所述，对于振动焊接设备10a和由该设备执行的振动焊接方法，由不同材料制成的树脂工件(即储存箱14和管道16)可在一个处理中同时焊接到仪表板12，同时防止仪表板12变形。由三种以上不同材料制成的树脂工件可在一个处理中焊接到仪表板12。
下面将描述根据本发明第二实施方式的振动焊接方法和振动焊接设备10b(图8)。根据第二实施方式的振动焊接设备10b的与根据第一实施方式的振动焊接设备10a相同的部件标有相同的附图标记，下面不再详细描述。
使用图8所示的振动焊接设备10b执行根据第二实施方式的振动焊接方法。
仪表板12具有复合曲面和相当大的面积。假设相对于振动板22的振动方向X的角度(第一倾角)称为θ1，相对于与方向X垂直的方向的角度(第二倾角)称为θ2。
基板20具有彼此隔开的多个独立的工件架21a至21h，用于在其上定位和放置作为工件的仪表板12，在仪表板12上放置储存箱14和管道16。仪表板12置于工件架21a至21h上，其产品设计表面12a面向下。工件架21a至21h例如由铝制成。
工件架21a、21b还支撑中央空气管16a的两个焊接件32b。中央空气管16a的两个焊接件32b沿着垂直于方向X的横向彼此略微隔开，并且分别由独立的工件架21a、21b支撑。工件架21a、21b相对于仪表板12的位置对应于仪表板12在其作为成品取向的前下部。工件架21a、21b各自的上表面用于支撑焊接件32b，这些上表面倾斜较大角度θ2。
工件架21c至21e支撑除霜器空气管16c的相应三对焊接件32b，其间插设有仪表板12。除霜器空气管16c的三对焊接件32b具有用于支撑仪表板12的相应上表面，这些上表面倾斜不同的角度θ1。具体地说，如图8所示，工件架21c的用于支撑右侧一对焊接件32b的上表面的角度θ1为正值，工件架21e的用于支撑左侧一对焊接件32b的上表面的角度θ1为负值。工件架21d的用于支撑中央一对焊接件32b的上表面的角度θ1为零。利用三个工件架21c至21e提供这些不同角度θ1。
工件架21f支撑储存箱14，在它们之间插设有仪表板12。
工件架21g、21h支撑左侧和右侧端部空气管16b的相应三对焊接件32b，仪表板12插设在它们之间。仪表板12的焊接相应端部空气管16b的部分的前表面将被覆盖预定的空气格栅，而且在仪表板12用作成品时这些前表面不可见。
保护件24安装在相应的工件架21a至21f上，即位于基板20与仪表板12之间，并且不安装在工件架21g、21h上。
如图8、9、10和11所示，每个保护件24的厚度根据树脂工件(即储存箱14或管道16)在被保护件24支撑的部位处的材料而异。具体地说，保护件24在其支撑由熔点较低的材料(TPO)制成的储存箱14的部位处具有较小厚度Ab1，在其支撑由熔点较高的材料(PP)制成的管道16的部位处具有较大厚度Ab2、Ab3、Ab4。保护件24的厚度与保护件24所处的角度无关，其指的是在与保护件24的表面正交的方向上的厚度。
保护件24的整个上表面光滑，以紧贴配合到仪表板12的产品设计表面12a。通过工件架21a至21h的高度将保护件24的厚度调整至包括零的范围。
保护件24的厚度基于工件架21a至21e的上表面的倾角θ1、θ2设定为不同的值，所述上表面在支撑所述材料(PP)制成的管道16的不同部位保持抵靠仪表板12。
具体地说，如图12所示，保护件24的厚度Ab是基于倾角θ1和倾角θ2由假想表面29而定的值，假想表面29可以是平坦或弯曲的。图12的视图表示随着倾角θ1的增大，厚度Ab以较高的速度增加，随着倾角θ2的增大，厚度Ab以较低的速度增加。表面29包括死区，在死区中在倾角θ1、θ2接近零时厚度Ab不增加。如果倾角θ1为θ1＝0，那么不管倾角θ2如何厚度Ab都为恒定。
图12所示的表面29设计成因不同倾角θ1、θ2而使在X方向以外的方向上的运动最小，从而允许储存箱14和管道16均匀焊接至仪表板12。表面29或基于倾角θ1、θ2计算厚度Ab的对应方程通过试验、计算、模拟等确定。由于表面29可提供沿两个垂直方向对应于倾角θ1、θ2的值，所以与仅基于一个角度提供该值相比，可更加精确地确定保护件24的厚度Ab。
图12所示的倾角θ1、θ2为绝对值，可代表正值或负值。如果仪表板12的产品设计表面12a包括弯曲表面或多个平坦表面，那么保护件24的厚度Ab可基于倾角θ1、θ2的平均值设定。
根据图12所示的表面29，厚度Ab3和厚度Ab4大于厚度Ab2。尽管图8中对于工件架21a、21b、21c、21e仅示出了倾角θ1、θ2之一，但其厚度Ab3和Ab4可基于复合角设定。
除表面29之外，可采用基于倾角θ1、θ2计算厚度Ab的对应方程或基于倾角θ1、θ2确定厚度Ab的映射表。例如，保护件24的厚度Ab可基于图13所示的映射表设定。基于倾角θ1、θ2从保护件24的厚度确定不同部位的垂直厚度，并考虑不同部位处的反作用力而调整垂直厚度，从而制成图13所示的映射表。图13所示的映射表可通过计算、试验和经验值生成。如果保护件24的厚度小于5mm，那么仪表板12可能会变形。因此，保护件24的厚度下限为5mm。
在工件架21g、21h上没有布置保护件24，因为在仪表板12作为成品组装在汽车中时仪表板12被工件架21g、21h支撑的部位会被其它部件遮住。因此，保护件24的材料量减少，从而还减少了更换保护件24所需的工作量。
下面描述利用这样构造的振动焊接设备10b通过振动焊接将储存箱14和管道16接合到仪表板12的振动焊接方法。
在预备处理中，将仪表板12定位并置于工件架21a至21h上。当保护件24安装在工件架21a至21f的上表面上时，仪表板12置于工件架21a至21f上，保护件24插设在它们之间。
然后，将储存箱14和管道16定位并置于仪表板12上。可选的是，在将仪表板12置于工件架21a至21h上之前，可将储存箱14和管道16定位并临时固定在仪表板12上，然后可将仪表板12置于工件架21a至21h上。
基板20在控制器26的控制下通过升降器31提升。基板20和振动板22的推杆22a将仪表板12的焊接肋30a和储存箱14的焊接件30b以成层方式夹持在其间并将仪表板12的焊接肋32a和管道16的焊接件32b以成层方式夹持在其间，并向这些焊接肋和焊接件施加压力。因保护件24的厚度而异的压力施加至焊接肋30a和焊接件30b的接触表面以及焊接肋32a和焊接件32b的接触表面。
然后，振动板22在控制器26的控制下以给定的幅度和频率沿水平方向X横向振动。当振动板22这样振动时，焊接肋30a和焊接件30b的接触表面以及焊接肋32a和焊接件32b的接触表面产生摩擦热，从而通过振动焊接接合在一起。
基于工件架21a至21e与仪表板12接触的表面的倾角θ1、θ2设定保护件24的适当厚度Ab2、Ab3、Ab4。因此，因不同倾角θ1、θ2而使在X方向以外的方向上的运动最小，从而将储存箱14和管道16均匀焊接至仪表板12。焊接区域的焊接质量提高，并且降低了振动焊接设备10b上的任何不当载荷，从而赋予其较长的使用寿命。
根据上述振动焊接方法，在基板20提升时，使推杆22a与储存箱14和管道16的焊接件30b、32b的上表面同时接触，从而向焊接件30b、32b施加相同的压力。然而，即使向焊接件30b、32b施加相同的压力，由于各种原因也不能在接触表面上产生适当的摩擦力。如图14所示，推杆22a可具有不同的长度Bb、Bb’以调整施加至焊接件30b、32b的压力。在图14中，长度Bb’略小于长度Bb，使得具有较小长度Bb’的推杆22a稍晚于具有较大长度Bb的推杆22a与对应焊接件32b接触。
在上述振动焊接设备10b中，仅在仪表板12上布置保护件24。根据设计条件，如图15所示，保护件24也可布置在储存箱14和管道16上。如果在储存箱14和管道16上布置有保护件24，那么可省去仪表板12上的保护件24。
对于根据第二实施方式的振动焊接设备10b和振动焊接方法，基于工件架21a至21e与仪表板12接触的表面的倾角θ1、θ2设定保护件24的适当厚度Ab2、Ab3、Ab4。因此，因不同倾角θ1、θ2而使在X方向以外的方向上的运动最小，从而将储存箱14和管道16均匀焊接至仪表板12。焊接区域的焊接质量提高，并且降低了振动焊接设备10b上的任何不当载荷以及非振动方向上的载荷，从而赋予其较长的使用寿命。
即使倾角θ1、θ2不同，通过振动焊接设备10b也会在一个焊接处理中将储存箱14和管道16焊接至仪表板12。因此，振动焊接设备10b成本较低，并且由其执行的振动焊接方法的步骤数量较少并因此而有效。
由于管道16具有多个焊接件32b，所以在一个处理中将管道16焊接至仪表板12方便而有效。
另外，对于根据第二实施方式的振动焊接设备10b和振动焊接方法，由于对应于倾角θ1、θ2的独立工件架21a至21f，即使仪表板12具有相当大的面积，也不需要在其整个表面上进行支撑。从而振动焊接设备10b结构相对简单，用于支撑仪表板12的支撑面积较小，并且保护件24所需的材料量较少。独立工件架21a至21f具有与仪表板12接触的独立表面。一些工件架，例如工件架21a、21b可具有共用基底(见图8)。
尽管仪表板12具有复合曲面，但是工件架21a至21f的上表面的面积较小，并且可近似为平坦表面。从而，可容易地设定保护件24的厚度Ab，并且用于工件架21a至21f上的保护件24可具有均匀厚度。工件架21a至21f的上表面可以是平坦的。工件架21a至21g可单独设计、制造、调整和维护。
下面将描述根据本发明第三实施方式的振动焊接方法和振动焊接设备10c(图16和17)。根据第三实施方式的振动焊接设备10c的与根据第一实施方式的振动焊接设备10a相同的部件标有相同的附图标记，下面不再详细描述。
使用图16所示的振动焊接设备10c执行根据第三实施方式的振动焊接方法。
如图16所示，仪表板12具有复合曲面和相当大的面积。
基板20具有彼此隔开的多个工件架132a至132h，用于支撑仪表板12的给定区域。工件架132a至132h朝向振动板22延伸。工件架132a至132h例如由铝制成。工件架132a至132h对应于根据上述第二实施方式的工件架21a至21h。
图18表示作为示例的工件架132d。如图18所示，工件架132d在其下端上具有从其相对两侧横向伸出的较宽翼部134。在较宽翼部134中限定有螺钉孔136。通过使螺钉138穿过螺钉孔136并拧入基板20而将工件架132d紧固至基板20。
垫片140作为间隔件插设在较宽翼部134与基板20之间。垫片140的尺寸与较宽翼部134基本相同，并且在其中限定有与相应螺钉孔136对准的螺钉孔141。垫片140也通过螺钉138紧固至基板20。
垫片140可由根据日本国家标准(JIS)的结构钢(例如SC50)或工具钢(例如SK5)制成。
工件架132a至132c和132e至132h在结构上与工件架132d相同。
与工件架132a至132h结合的垫片140的厚度根据工件架132a至132h支撑树脂工件的部位而异。具体地说，垫片140在支撑由熔点较低的材料(TPO)制成的储存箱14的工件架132f处具有较小厚度，在支撑由熔点较高的材料(PP)制成的管道16的工件架132a至132e、132g、132h处具有较大厚度。垫片140的不同厚度对于调整工件架132a至132h的上表面的位置是有效的。
各个工件架132a至132h不必与单个垫片140结合。如果要向工件架施加高压力，那么工件架可与多个垫片140结合。如果要向工件架施加特别低的压力，那么工件架可不结合垫片。因此，垫片的厚度可调整至包括零的范围。
如图16所示，工件架132a、132b支撑中央空气管16a的两个焊接件32b，这两个焊接件32b沿着垂直于方向X的横向彼此略微隔开。工件架132a、132b相对于仪表板12的位置对应于仪表板12在其作为成品取向的前下部。工件架132a、132b各自的上表面倾斜较大角度θ2。
工件架132c至132e支撑除霜器空气管16c的相应成对焊接件32b，仪表板12插设在它们之间。除霜器空气管16c的成对焊接件32b具有用于在其上支撑仪表板12的相应上表面，这些上表面倾斜不同的角度θ1。具体地说，如图16所示，工件架132c的用于支撑右侧一对焊接件32b的上表面的角度θ1为正值，工件架132e的用于支撑左侧一对焊接件32b的上表面的角度θ1为负值。工件架132d的用于支撑中心一对焊接件32b的上表面的角度θ1为零。利用三个工件架132c至132e提供这些不同角度θ1。
工件架132f支撑储存箱14，在它们之间插设仪表板12。
工件架132g、132h支撑左侧和右侧端部空气管16b的相应焊接件32b，仪表板12插设在它们之间。仪表板12的焊接相应端部空气管16b的部分的前表面将被覆盖预定的空气格栅，而且在仪表板12用作成品时这些前表面不可见。
保护件24安装在相应的工件架132a至132h的上表面上。
如图19所示，振动板22具有从面向基板20的端面朝向基板20伸出的多个推杆144。推杆144相当于推杆22a。各个推杆144在其面向振动板22的上端上具有从其相对两侧横向伸出的较宽翼部146。在较宽翼部146中限定有螺钉孔148。通过使螺钉150穿过螺钉孔148并拧入振动板22而将推杆144紧固至振动板22。垫片140(见图18)也可作为间隔件插设在较宽翼部146与振动板22之间。然而，根据第三实施方式，在较宽翼部146与振动板22之间没有插设垫片140。
与工件架132a至132h一样，推杆144例如由铝制成。
根据第三实施方式的振动焊接设备10c基本如上所述构成。下面将描述振动焊接设备10c的操作和优点。
仪表板12置于工件架132a至132h上。由于保护件24布置在工件架132a至132h的上表面上，所以仪表板12置于工件架132a至132h上，保护件24插设在它们之间。
然后，将储存箱14和管道16定位并置于仪表板12上。可选的是，在将仪表板12置于工件架132a至132h上之前，可将储存箱14和管道16定位并临时固定在仪表板12上，然后可将仪表板12置于工件架132a至132h上。
在以上预备处理之后，通过振动焊接设备10c执行振动焊接处理。具体地说，在控制器26的控制下致动升降器31，以朝向振动板22提升基板20。
基板20被提升，直到最后基板20和振动板22的推杆144将仪表板12的焊接肋30a和储存箱14的焊接件30b以成层方式夹持在其间并将仪表板12的焊接肋32a和管道16的焊接件32b以成层方式夹持在其间，并向这些焊接肋和焊接件施加压力。向焊接肋30a和焊接件30b的接触表面以及焊接肋32a和焊接件32b的接触表面施加因垫片140的厚度而异的压力。
然后，振动板22在控制器26的控制下通过振动装置27以给定幅度和频率沿水平方向X横向振动。当振动板22这样振动时，焊接肋30a和焊接件30b的接触表面以及焊接肋32a和焊接件32b的接触表面产生摩擦热，从而通过振动焊接接合在一起。
如上所述，垫片140在支撑由熔点较低的TPO制成的储存箱14的工件架132f处具有较小厚度，在支撑由熔点较高的PP制成的管道16的工件架132a至132e、132g、132h处具有较大厚度。因此，施加到工件架132f(焊接件30b)的压力较低，施加到工件架132a至132e、132g、132h(焊接件32b)的压力较高。
当储存箱14和管道16通过振动焊接接合到仪表板12上时，从熔点较低的焊接件30b熔化的材料量和从熔点较高的焊接件32b熔化的材料量基本彼此相等。因此，储存箱14和管道16基本均匀地接合到仪表板12。
根据第三实施方式，需要施加高压的管道16和需要施加低压的储存箱14可在一个处理中接合至仪表板12。换言之，不必在不同的处理中接合管道16和储存箱14。通过振动焊接设备10c执行的振动焊接方法的步骤数量较少，在振动焊接设备10c上制造成品所需的时间较短。
在振动焊接处理期间，仪表板12保持与保护件24摩擦接触。然而，由于保护件24由氨基甲酸乙酯制成并具有光滑柔顺表面和润滑能力，所以保护仪表板12的产品设计表面12a不被擦伤。
在振动板22振动给定时间之后，或者在从焊接肋30a、32a以及焊接件30b、32b熔化给定材料量之后，振动板22停止振动。致动升降器31以降低基板20，并将已经接合在一起的仪表板12、储存箱14和管道16作为焊接产品移除。在焊接产品中，储存箱14和管道16的焊接件30b、32b充分熔化在仪表板12中以获得足够的焊接强度水平。然而，振动焊接设备10c防止储存箱14和管道16的焊接件30b、32b熔化过深，因此仪表板12的产品设计表面12a不会变形。
如果在重复进行以上振动焊接过程之后工件架132a至132h上的任何保护件24磨损，则可用新的保护件替换磨损的保护件24。由于保护件24的面积较小，可容易地替换并且成本较低。
振动焊接设备10c能够处理形状与仪表板12不同的仪表板，例如具有曲率半径不同的曲面的仪表板，由于待接合的树脂工件的熔点较低而具有受到较低压力的区域的仪表板，或者由于待接合的树脂工件的熔点较高而具有受到较高压力的区域的仪表板，振动焊接设备10c能够通过改变布置在用于支撑这些区域的工件架上的垫片140的厚度和数量而对仪表板进行处理。
当工件架132a至132h在基板20上彼此隔开时，垫片140可比在安装在单个一体式工件架与基板20之间的情况下更容易安装在适当位置。此外，设定垫片140的厚度时不需要考虑仪表板12和管道16在制造时产生的尺寸误差。
在上述第三实施方式中，在振动板22与推杆144之间没有插设垫片140。然而如上所述，垫片140可插设在振动板22与推杆144之间，以调整推杆144从振动板22伸出的距离，从而调整施加到仪表板12的对应区域的摩擦力。
树脂基底不限于仪表板12，也可以是其它部件。树脂工件不限于储存箱14和管道16，也可以是其它树脂工件。
保护件24也可安装在推杆144的远端面上。如果保护件24安装在推杆144的远端面上，则可省去工件架132a至132h上的保护件24。
不需要在所有工件架132a至132h与基板20之间插设垫片140。具体地说，对仪表板12的施加特别小的压力的区域进行支撑的那些工件架不需要结合垫片140。
本发明不限于同时将多个熔点不同的树脂工件接合到树脂基底的振动焊接处理，而是还可应用于将多个熔点相同的树脂工件接合到树脂基底的平坦和倾斜表面上的振动焊接处理。在不存在垫片140时，推杆或振动板施加到平坦表面上的压力高于施加到倾斜表面上的压力。然而，可通过增加与位于倾斜表面处的工件架或推杆相结合的垫片140的厚度而使施加到平坦表面和倾斜表面上的压力相等。
虽然已经详细示出并描述了本发明的某些优选实施方式，但应理解可在不脱离所附权利要求范围的情况下进行各种修改和变更。

Claims (20)

1、一种振动焊接方法，该振动焊接方法用于通过在第一振动件(20)和第二振动件(22)之间以成层方式夹持树脂基底(12)和树脂工件(14，16)，然后使所述第一振动件(20)和所述第二振动件(22)相对于彼此振动，从而利用振动在压力下使所述树脂基底(12)和所述树脂工件(14，16)彼此焊接，该振动焊接方法包括以下步骤：
使至少两个所述树脂工件(14，16)保持与所述树脂基底(12)接触；并且
在所述树脂基底(12)与所述第一振动件(20)之间以及/或者在所述树脂工件(14，16)与所述第二振动件(22)之间设置保护件(24)，
其中所述保护件(24)的厚度根据该保护件(24)支撑所述树脂基底(12)和/或所述树脂工件(14，16)的部位而异。
2、根据权利要求1所述的振动焊接方法，其中，与所述树脂基底(12)保持接触的所述至少两个树脂工件(14，16)由不同材料制成，并且
所述保护件(24)的厚度根据所述树脂工件(14，16)在被该保护件(24)支撑的部位处的材料而异。
3、根据权利要求1所述的振动焊接方法，其中，所述保护件(24)包括氨基甲酸乙酯件。
4、根据权利要求1所述的振动焊接方法，其中，当所述树脂工件(14，16)在被所述保护件(24)支撑的部位处的熔点较低时，所述保护件(24)的厚度较小。
5、根据权利要求1所述的振动焊接方法，其中，基于所述树脂基底(12)在被所述保护件(24)支撑的部位处面对其中一个所述振动件的接触表面的倾角，设定所述保护件(24)的厚度。
6、根据权利要求5所述的振动焊接方法，其中，所述保护件(24)的厚度由相对于所述第一振动件(20)和所述第二振动件(22)相对彼此振动的方向的第一倾角(θ1)和相对于前述方向的垂直方向的第二倾角(θ2)限定。
7、根据权利要求6所述的振动焊接方法，该振动焊接方法还包括以下步骤：
使所述树脂工件(14，16)在至少两个部位保持与所述树脂基底(12)接触，该树脂基底(12)的面对所述第一振动件(20)的接触表面的倾角在所述两个部位处不同；
将所述树脂基底(12)置于所述第一振动件(20)上的独立工件架(21a至21h)上，所述独立工件架(21a至21h)取决于所述两个部位处的倾角；以及
将所述保护件(24)置于所述独立工件架(21a至21h)中的与至少一个产品设计表面(12a)保持接触的独立工件架上。
8、根据权利要求7所述的振动焊接方法，其中，至少一个所述独立工件架(21a至21h)未设置所述保护件(24)。
9、根据权利要求1所述的振动焊接方法，该振动焊接方法还包括以下步骤：
设置用于仅支撑所述树脂基底(12)的预定区域的多个工件架(132a至132h)，这些工件架(132a至132h)从所述第一振动件(20)的面对所述第二振动件(22)的表面朝向所述第二振动件(22)伸出；
设置用于向所述树脂基底(12)和所述树脂工件(14，16)施加压力的多个杆(144)，这些杆(144)从所述第二振动件(22)的面对所述第一振动件(20)的表面朝向所述第一振动件(20)伸出，其中可至少在所述第一振动件(20)与所述工件架(132a至132h)之间插设间隔件(140)；并且
调整所述间隔件(140)的厚度以设定所述工件架(132a至132h)的上端面的位置。
10、根据权利要求1所述的振动焊接方法，其中，所述保护件(24)布置在所述树脂基底(12)的产品设计表面(12a)上或所述树脂工件(14，16)上。
11、根据权利要求1所述的振动焊接方法，其中，所述树脂基底(12)由聚丙烯制成，所述树脂工件(14，16)由聚丙烯和热塑性烯烃制成。
12、一种振动焊接设备，该振动焊接设备用于利用振动在压力下使树脂基底(12)和树脂工件(14，16)彼此焊接，该振动焊接设备包括：
第一振动件(20)和第二振动件(22)，这些振动件用于在相对彼此振动的同时将所述树脂基底(12)和所述树脂工件(14，16)以成层方式夹持在其间，其中至少两个所述树脂工件(14，16)保持与所述树脂基底(12)接触；以及
保护件(24)，该保护件布置在所述树脂基底(12)与所述第一振动件(20)之间以及/或者在所述树脂工件(14，16)与所述第二振动件(22)之间，其中所述保护件(24)的厚度根据该保护件(24)支撑所述树脂基底(12)和/或所述树脂工件(14，16)的部位而异。
13、根据权利要求12所述的振动焊接设备，其中，与所述树脂基底(12)保持接触的所述至少两个树脂工件(14，16)由不同材料制成，并且
所述保护件(24)的厚度根据所述树脂工件(14，16)在被该保护件(24)支撑的部位处的材料而异。
14、根据权利要求12所述的振动焊接设备，其中，所述保护件(24)包括氨基甲酸乙酯件。
15、根据权利要求12所述的振动焊接设备，其中，当所述树脂工件(14，16)在被所述保护件(24)支撑的部位处的熔点较低时，所述保护件(24)的厚度较小。
16、根据权利要求12所述的振动焊接设备，其中，基于在所述保护件(24)支撑该树脂基底(12)的部位处所述树脂基底(12)与其中一个所述振动件接触的表面的倾角，设定所述保护件(24)的厚度。
17、根据权利要求16所述的振动焊接设备，其中，所述保护件(24)的厚度由相对于所述第一振动件(20)和所述第二振动件(22)相对彼此振动的方向的第一倾角(θ1)和相对于前述方向的垂直方向的第二倾角(θ2)限定。
18、根据权利要求17所述的振动焊接设备，其中，所述树脂工件(14，16)在至少两个部位处保持与所述树脂基底(12)接触，该树脂基底(12)与所述第一振动件(20)接触的表面的倾角在所述两个部位处不同；
所述树脂基底(12)被置于所述第一振动件(20)上的独立工件架(21a至21h)上，所述独立工件架(21a至21h)取决于所述两个部位处的倾角；以及
所述保护件(24)被置于所述独立工件架(21a至21h)中的保持与至少一个产品设计表面(12a)接触的独立工件架上。
19、根据权利要求18所述的振动焊接设备，其中，至少一个所述独立工件架(21a至21h)未设置所述保护件(24)。
20、根据权利要求12所述的振动焊接设备，该振动焊接设备还包括：
用于支撑所述树脂基底(12)的预定区域的多个工件架(132a至132h)，这些工件架(132a至132h)从所述第一振动件(20)的面对所述第二振动件(22)的表面朝向所述第二振动件(22)伸出；以及
用于向所述树脂基底(12)和所述树脂工件(14，16)施加压力的多个杆(144)，这些杆(144)从所述第二振动件(22)的面对所述第一振动件(20)的表面朝向所述第一振动件(20)伸出，
其中可至少在所述第一振动件(20)与所述工件架(132a至132h)之间插设间隔件(140)；并且
调整所述间隔件(140)的厚度以设定所述工件架(132a至132h)的上端面的位置。
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