CN101898420B - 用于制造树脂模具组件的方法 - Google Patents

用于制造树脂模具组件的方法 Download PDF

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Publication number
CN101898420B
CN101898420B CN201010193050.8A CN201010193050A CN101898420B CN 101898420 B CN101898420 B CN 101898420B CN 201010193050 A CN201010193050 A CN 201010193050A CN 101898420 B CN101898420 B CN 101898420B
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China
Prior art keywords
welding region
laser beam
mold assembly
manufacture
assembly according
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CN201010193050.8A
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CN101898420A (zh
Inventor
鉾田和晃
财津吉裕
梅山辰也
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Stanley Electric Co Ltd
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Stanley Electric Co Ltd
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Priority claimed from JP2009129901A external-priority patent/JP5436937B2/ja
Priority claimed from JP2009247402A external-priority patent/JP5363944B2/ja
Application filed by Stanley Electric Co Ltd filed Critical Stanley Electric Co Ltd
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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
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • 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
    • B29C65/1638—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 focusing the laser beam on the interface
    • 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
    • B29C65/1661—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined scanning repeatedly, e.g. quasi-simultaneous laser 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
    • B29C65/1664—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
    • 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
    • B29C66/10—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
    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt joints
    • 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
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/23—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations
    • B29C66/232—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations said joint lines being multiple and parallel, i.e. the joint being formed by several parallel joint lines
    • 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
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/24—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight
    • B29C66/242—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours
    • B29C66/2422—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being circular, oval or elliptical
    • B29C66/24221—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being circular, oval or elliptical being circular
    • 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
    • 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
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/32—Measures for keeping the burr form under control; Avoiding burr formation; Shaping the burr
    • 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
    • B29C66/32—Measures for keeping the burr form under control; Avoiding burr formation; Shaping the burr
    • B29C66/326—Shaping the burr, e.g. by the joining tool
    • 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
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    • B29C66/342—Preventing air-inclusions
    • 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
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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
    • B29C66/347—General aspects dealing with the joint area or with the area to be joined using particular temperature distributions or gradients; using particular heat distributions or gradients
    • B29C66/3472—General aspects dealing with the joint area or with the area to be joined using particular temperature distributions or gradients; using particular heat distributions or gradients in the plane of the joint, e.g. along the joint line in the plane of the joint or perpendicular to the joint line in the plane of the joint
    • 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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    • B29C66/3474—General aspects dealing with the joint area or with the area to be joined using particular temperature distributions or gradients; using particular heat distributions or gradients perpendicular to the plane of the joint
    • 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
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B29C66/542—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles joining hollow covers or hollow bottoms to open ends of container bodies
    • 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
    • B29C66/65—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 with a relative motion between the article and the welding tool
    • B29C66/652—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 with a relative motion between the article and the welding tool moving the welding tool around the fixed article
    • 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
    • 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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    • B29C66/81266—Optical properties, e.g. transparency, reflectivity
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/8145—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 constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81457—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 constructional aspects of the pressing elements, e.g. of the welding jaws or clamps comprising a block or layer of deformable material, e.g. sponge, foam, rubber
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
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    • B29C66/9121—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature
    • B29C66/91221—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature of the parts to be joined
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91411—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the parts to be joined, e.g. the joining process taking the temperature of the parts to be joined into account
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91441—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature the temperature being non-constant over time
    • B29C66/91443—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature the temperature being non-constant over time following a temperature-time profile
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9161—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux
    • B29C66/91641—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux the heat or the thermal flux being non-constant over time
    • B29C66/91643—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux the heat or the thermal flux being non-constant over time following a heat-time profile
    • B29C66/91645—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux the heat or the thermal flux being non-constant over time following a heat-time profile by steps
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    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B29C66/9192—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B29C66/9192—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams
    • B29C66/91951—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to time, e.g. temperature-time diagrams
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/93—Measuring or controlling the joining process by measuring or controlling the speed
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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
    • B29C66/90—Measuring or controlling the joining process
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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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/96—Measuring or controlling the joining process characterised by the method for implementing the controlling of the joining process
    • B29C66/961—Measuring or controlling the joining process characterised by the method for implementing the controlling of the joining process involving a feedback loop mechanism, e.g. comparison with a desired value
    • 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
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    • 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
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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
    • 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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    • 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
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    • 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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    • B29C65/02—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
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    • 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
    • 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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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
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    • 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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    • 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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    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
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    • B29C66/90—Measuring or controlling the joining process
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    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B29C66/9192—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams
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    • B29C66/91941—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to Tg, i.e. the glass transition temperature, of the material of one of the parts to be joined
    • 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
    • B29C66/90—Measuring or controlling the joining process
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    • B29C66/9192—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams
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    • B29C66/91943—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to Tg, i.e. the glass transition temperature, of the material of one of the parts to be joined higher than said glass transition temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/90—Measuring or controlling the joining process
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/90—Measuring or controlling the joining process
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/90—Measuring or controlling the joining process
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29K2033/00—Use of polymers of unsaturated acids or derivatives thereof as moulding material
    • B29K2033/04—Polymers of esters
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Abstract

本发明提供一种用于制造树脂模具组件的方法，在制造该树脂模具组件时，将透光树脂构件的第一焊接区域与吸光树脂构件的第二焊接区域彼此面对地布置，所述透光树脂构件的所述第一焊接区域与所述吸光树脂构件的所述第二焊接区域在相互面对的方向上挤压接触，扫描激光束，以使所述激光束入射在所述透光树脂构件上，并且反复照射在所述第二焊接区域上，以同步加热并熔化整个所述第一焊接区域和第二焊接区域，由此焊接所述透光树脂构件和所述吸光树脂构件。

Description

用于制造树脂模具组件的方法
技术领域
本发明涉及一种树脂模具组件的制造方法。
背景技术
例如，车辆灯具通常为由焊接在一起的壳体和透镜组成的树脂模制品，壳体由诸如丙烯腈-苯乙烯-丙烯酸酯共聚物(ASA)的吸光树脂制成，透镜由例如聚甲基丙烯酸甲酯(PMMA)的透光树脂制成。
JP-A-10-310676提出一种在热板焊接期间能够抑制蛛网现象的壳体组件，在该壳体组件中，热板夹设在透镜与壳体之间，以加热并熔化透镜和壳体，并且之后移除热板以焊接透镜和壳体。
JP-A-2000-294013提出一种激光焊接，其中，透镜和灯体(壳体)处于挤压状态，机器人从透镜侧朝灯体表面照射激光束，以加热并熔化灯体，灯体的熔化热还使透镜侧的密封脚的前部熔化，因此激光束沿透镜的整个外周扫描。
该公报描述了可在灯体的接收面上形成定位槽，以防止密封脚移位，从而能够在保持预定位置关系的状态下进行激光焊接，并且即使产生一些毛刺，也能够将这些毛刺限制在定位槽中。
JP-A-2001-243812提出使透镜的密封脚与灯体的接收面之间的结合面倾斜，以产生滑动并加宽射束直径。
JP-A-2004-349123提出一种利用激光束焊接壳体和透镜的方法(包括透镜具有曲面的情况)，在该方法中，在透镜的待与壳体结合的表面上布置与透镜形状相配的弹性导光构件和平坦透明板，通过平坦透明板向弹性导光构件和透镜施加压缩负载，以使弹性导光构件紧密接触透镜，并且激光束通过弹性导光件和透镜从平坦透明板侧照射，以加热并熔化透镜与壳体的接触区域。
不能说用激光束焊接树脂模具组件的方法已取得充分发展。
期望提供一种通过利用激光束制造包括透光树脂构件和吸光树脂构件的树脂模具组件的方法，其中，树脂模具组件具有紧密的粘附性、优良的外观和高结合强度。
发明内容
根据本发明的一个方面，提供一种用于制造树脂模具组件的方法，该方法包括下列步骤：
将透光树脂构件布置在吸光树脂构件上，使所述透光树脂构件的第一焊接区域面向所述吸光树脂构件的第二焊接区域；
在所述透光树脂构件与所述吸光树脂构件之间施加压力，以使所述透光树脂构件的所述第一焊接区域与所述吸光树脂构件的所述第二焊接区域在相互面对的方向上挤压接触；并且
通过所述透光树脂构件在所述吸光树脂构件的所述第二焊接区域上施加激光束，并在所述第二焊接区域的整个面积上扫描所述激光束，以在所述第二焊接区域上反复照射所述激光束，从而同步加热并熔化整个所述第一焊接区域和第二焊接区域，并且焊接所述透光树脂构件和所述吸光树脂构件。
伸展的焊接区域可沿所述焊接区域的宽度方向被分成多条焊线。
所述焊接区域可在所述宽度方向上倾斜，以均化照射能量密度。
可在所述焊接区域的宽度方向上形成温度梯度，以调节熔融树脂的流动。
由于整个焊接区域同步熔化，因此可能获得增强的焊接，并且从透光树脂构件与吸光树脂构件之间的区域有效地去除间隙。可优选在一侧处调节毛刺的形成。
附图说明
图1A至1F是示出通过向布置在平面上的(二维)焊接区域照射由电流镜扫描的激光束来进行焊接的图、加工目标组件的剖视图、焊接平面的俯视图、示出接受试验照射的样品的结构的示意立体图、示出试验照射的测量结果的曲线图以及示出用于焊接圆条形区域的激光束扫描的图。
图2A是示出吸光树脂的体积随温度变化的曲线图，图2B至2D是示出因激光束反复照射造成的抵接树脂构件的形状变化的剖视图，图2E是示出吸光树脂的温度变化相对于激光束反复照射的时间的曲线图。
图3A和3B是示出通过向三维焊接区域反复照射激光束而焊接的示意立体图和剖视图，图3C至3E是示出修改例的剖视图和图示。
图4A至4C是激光焊接设备的示意侧视图、焊接区域的俯视图以及在焊接区域中具有温度分布的组件的剖视图，用于示出本发明人利用机器人对激光束焊接的研究。
图5是示出在不同的入射角下时间吸光树脂的温度变化相对于激光束反复照射的曲线图。
图6A至6C是示出随着距激光源的距离的变化入射角的变化、以及补偿该入射角变化的方法的图。
图7A至7C是示出当焊接区域在均匀温度下熔化时液体流动的示意平面图、示出形成毛刺的示意剖视图以及示出当焊接区域设置有单调温度梯度时液体流动的示意平面图。
图8A至8C是示出通过向布置在二维平面上的焊接区域照射激光束来焊接并在焊接区域的宽度方向上形成温度梯度的示意剖视图、焊接平面的平面图以及示出相应焊线的平均温度的通用或总体变化的曲线图。
图9是示出通过激光束的反复照射在焊接区域的宽度方向上具有温度梯度的焊接修改例的图。
具体实施方式
透光(透明)树脂构件和吸光(不透明)树脂构件在挤压或加压状态下彼此面对并接触，激光束从透光树脂侧照射。激光束穿过透光树脂构件并到达吸光树脂构件。激光束被吸收在吸光树脂构件中并向该吸光树脂构件发热。因此，吸光树脂构件被加热、软化并熔化。由于透光树脂构件在加压状态下与吸光树脂构件接触，因此，吸光树脂构件中的热还传递到透光树脂构件。透光树脂构件因此也软化，接触区域增大，并最终使透光树脂构件也熔化。该两个构件被熔化并焊接。本发明人已研究出利用机器人的激光焊接方法。
图4A是示出利用机器人的激光焊接设备的结构的侧视图。聚光光学系统102包括膨胀器，聚光透镜系统与连接到激光源的光纤101的远端连接，并发射会聚激光束103。聚光光学系统102由机器人104握持，并执行包括聚光光学系统的三维位置和激光束的传播方向在内的六维控制。基部105支撑机器人104和壳体夹具106。夹具106支撑由吸光树脂制成的壳体108。由透光树脂制成的透镜109布置在壳体108上。透镜109和壳体108保持在加压状态下。
机器人104将聚光光学系统102定位在预定起始点，发射激光束103而使激光束通过透镜109照向壳体108。壳体108的用激光束照射的表面区域吸收激光束并被加热、软化和熔化。与已加热的壳体108接触的透镜109也被加热。
如图4B所示，设置在透镜109的外周部的焊接区域110通常为环形。激光在起始点处开始照射，机器人104沿环移动聚光光学系统，并且在移动过环的一圈之后，终止焊接加工。
如图4C中所示，当激光束传播时，在壳体108(和透镜109)的焊接区域110中形成熔化区域111和在熔化区域之前或之后的软化(玻璃化转变)区域112和113。在熔化区域111中，透镜和壳体的树脂构件熔化并略微被压下或变形。在激光焊接中，变形区域的高度大约为0.1mm以下。
树脂构件表面通常具有类似焊线的突出模具区域和非平坦区域。壳体上表面上的非平坦区域由108r表示，透镜下表面上的非平坦区域由109r表示。突出高度通常大约为0.2mm。激光束还未穿过的区域呈固相，并且突出阶梯仍未变形。在突出阶梯附近阻碍透镜与壳体之间的接触，因此可能保留间隙。如果不去除间隙，则可能不能进行良好焊接。即使激光束沿焊接区域移动一圈，但仍可能留下未被焊接的区域，并且焊接状态为非气密。
人们认为因为由激光束照射产生的加热和熔化仅在焊接区域中的局部发生，所以形成了该局部焊接缺陷。如果整个焊接区域能够象热板焊接一样被同时加热并熔化，则预期能够改善局部焊接缺陷。
本发明人已研究出激光束的高速扫描，以加热并熔化整个焊接区域。如果激光束以一定的间隔反复照射焊接区域而不允许目标冷却下来，则预期焊接区域的温度会升高。然而考虑到机器人难以执行这样的高速扫描。可应用电扫描器结构来实现激光束的该高速扫描。
图1A是示出使用电扫描器的激光束焊接设备的结构的示意图。调焦光学系统13布置成面向从与激光振荡器连接的光纤11的远端照射的激光束12。调焦光学系统包括可动透镜，该可动透镜允许调节光路上的焦点位置。第一电流镜14布置成面向从调焦光学系统13照射的激光束，以例如在加工目标平面上进行x-方向扫描。第二电流镜15布置成面向从第一电流镜14反射的激光束，以例如在加工目标平面上进行y-方向扫描。
控制设备控制电流镜14和15以及调焦光学系统13。发射的激光束12s能够通过电流镜14和15在xy平面上进行二维扫描，并且能够借助调节调焦光学系统13的调节通过控制焦距而沿z-方向移动焦点位置。即，会聚激光束能够进行三维扫描。电流镜重量轻，并且能够进行高速扫描。
激光振荡器可以是两重或三重波YAG、半导体激光器、光纤激光器等的激光振荡器。如果仅使用二维扫描，则可使用配备有fθ透镜的扫描头来代替调焦光学系统。
图1B是示出加工具有布置在二维平面上的焊接区域的目标组件或制品的示意剖视图。透镜22布置在由吸光树脂制成的器皿形状的壳体21上，透镜由透光树脂制成，覆盖壳体21的开口并面向壳体。在该实施例中，在透镜22的下表面上形成焊接肋23。肋23不是必要的构成元件。透明压力板25布置在透镜22上，以使透镜22的下表面与壳体21的上表面以压力P挤压接触。激光束12s穿过透光压力板25和透镜22，并照射在与肋23接触的壳体21的上表面上。通过驱动电流镜沿肋(焊接区域)扫描照射位置。布置焊接区域的平面由xy平面表示。在图1A中所示的结构中，第一电流镜14沿x-方向进行扫描，第二电流镜15沿y-方向进行扫描。
图1C示出二维焊接区域27的形状的实施例，该形状是由圆条表示的环形。激光束反复照射扫描所述环。将加工目标制品放置在合适位置之后，同一位置受到激光束多次照射，从其中待焊接的树脂构件的温度处于初始温度的状态直到其中焊接区域达到熔化状态的状态。例如，同一位置受到激光束的多次照射，直到该同一位置到达软化温度(玻璃化转变温度)时为止，并且进一步受到激光束的多次照射直到同一位置到达熔化状态为止。通过逐渐提高吸光树脂的温度还可以抑制形成气泡。
如图1D中所示，形成样品作为试验件，样品使由透光树脂形成的透镜22s布置在由吸光树脂形成的壳体21s上。在吸光树脂壳体21s与透光树脂透镜22s的相对表面的每个上形成肋。样品的焊接区域(即，透镜22s与壳体21s的肋之间的接触表面)的长度为15cm，宽度为2cm。对样品进行试验照射。壳体的肋的宽度为3cm，具有宽度为2cm且高度为1cm的肋的透镜布置在壳体上。透镜由PMMA制成，壳体由ASA制成。利用夹设在透镜与壳体之间的热电偶测量温度。以输出功率为200W且扫描速率为4m/sec的激光连续进行20次激光束照射。激光束通过电流镜在焊接平面上的定位精度为50μm以下。一次扫描所需的时间为37.5msec。设想实物的焊线的一次扫描超过1m。在该试验照射中，在焊线的每次扫描照射之后插入恒定间隔，以模拟一部分实物的焊接加工。在试验照射中，作为间隔插入大约为0.8秒。
图1E是示出样品的测量温度ts随时间变化的曲线图。例如，激光束每照射一次温度升高大约40度，并且在照射之后温度开始下降。由于下一个激光束在温度下降到照射之前的温度之前照射，因此，温度又再次升高。通过反复的激光束照射，平均温度逐渐升高。由于平均温度升高，因此每一次激光束照射的温升范围下降，并且整体变化形状成为向上凸起形状。当焊接区域中的位置变化时，以略微的时移实现类似的温度变化。显而易见的是，整个焊接区域能够同时被近似均匀地加热。试验之后，分开透镜和壳体以取出热电偶。尽管在图中已示出用热电偶测得的温度，但破坏试验表示透镜和壳体的良好焊接，并且设想实际温度比图中所示的温度高，达到240℃以上。
图1F是示出通过具有直线传播的电流镜的光学系统置换反射的图。可以考虑到，第一电流镜14的激光束入射位置是虚拟激光束光源的位置。电流镜14和15的旋转(摆动)扫描二维平面中的激光照射位置。由于虚拟激光源在xy平面中的位置与圆条形焊接区域的中心对准，因此，入射角θ在圆条形焊接区域中的任意位置处恒定。由于进行恒定速率的扫描，因此，每单位时间的入射能量在圆条形焊接区域中的任意位置处恒定。
如果焊接区域的形状是较大地改变与虚拟激光源的距离的形状，则入射角变化，照射面积也将变化。如果进行恒定速率扫描，则每单位时间和单位面积的入射能量随位置而变化，所到达的温度也将变化。在该情形下，优选的是，根据入射角或距虚拟激光源的距离控制扫描速率，以降低在入射能量密度下降的位置处的扫描速率，并且统一化焊接区域中的温度，该控制可通过控制设备16进行。
图2A是示出ASA树脂的体积与温度之间的关系的曲线图。纵坐标代表ASA树脂的体积，横坐标代表温度。在从室温开始的一些温度范围内，体积随着温度逐渐且几乎线性地增加。当温度超过负载挠曲温度(热变形温度)时，体积增加率增大，并且在温度超过玻璃化转变温度(软化温度)之后，体积增加率以较陡的梯度变成几乎线性的体积增加率。所使用的ASA是普通等级，负载挠曲温度大约为95℃，240℃属于流体区。
图2B至2D示出焊接区域中的假想变化。图2B示出软化之前的状态。由于壳体20与透镜22的突出阶梯，因此在壳体20与透镜22之间存在间隙。图2C示出壳体的温度超过软化点且在熔化之前的状态。壳体的整个焊接区域可变形，树脂通过施加的压力而可变平，壳体20与透镜22之间的间隙减小。图2D示出熔化状态。由于整条焊线进入熔化状态(至少为软化状态与熔化状态的结合)，因此，壳体20与透镜22之间的间隙消失，预期熔融的树脂构件21和22熔化并混合在一起，而使交界面消失。预期很可能获得加强的焊接，并且壳体20与透镜22之间难以留有间隙。
图2E是简要地示出温度随时间变化的曲线图。实线表示因反复的激光束照射造成的温度变化。从时间t0至t1，由于激光束反复地照射，因此温度与图1E中所示的类似重复地升降，并且平均温度升高。从时间t1至t2，熔化区域扩大，至少在升温状态下，吸光树脂进入熔融状态，两个树脂构件被推到一起。在时间t2处，焊接完成，温度通过自然冷却而回落。
为了对比，用虚线表示当机器人沿焊线一圈进行激光照射时的对比温度变化。在照射激光束时，因此吸光树脂的温度在时间t3处在单个激光发射中上升到熔融温度。即使当位于照射位置处的树脂进入熔融状态时，在其它位置仍未照射激光束，或者温度下降，从而其它位置处的树脂呈固相。因此限制了树脂构件的相互推动，并难以完全去除局部间隙。
由于在同一焊线上进行激光束的反复照射，因此整条焊线的温度同步或同时升高。树脂构件同步或同时软化并熔化，从而两个树脂构件相互推动，并且有效地去除局部间隙。
图3A是示出通过三维扫描的激光速焊接的示意图。从激光振荡器10照射的激光束通过光纤12引到扫描头31。扫描头31的结构包括调焦光学系统、x-方向的电流镜、y-方向的电流镜以及图1A中所示的控制设备。由吸光树脂制成的壳体21布置在夹具36上。壳体的焊接区域为三维结构，而不能容纳在二维平面中。由透光树脂制成并具有与壳体21的焊接区域对应的焊接区域的透镜22布置在壳体21上，使两个焊接区域彼此面对。在压力P下沿接触方向挤压透镜22和壳体21。
扫描头31沿焊接区域扫描激光束12s，以反复照射激光束。电流镜14和15控制二维xy平面中的位置，调焦光学系统13控制z-方向的焦距，以保持恒定的聚焦条件。
图3B示出聚焦条件的实施例。在所谓的后焦点状态下，会聚的激光束12s的焦点位置在焊接区域27的后方。对焊接区域散焦使大面积的焊接区域被照射并熔化，以获得增强的结合。通过取代后焦点的前焦点可获得散焦。
作为一实施例，对具有三维结构的车辆后组合灯具进行焊接加工。由透光树脂材料制成的透镜和由吸光树脂材料制成的壳体在三维结构的焊接区域处被焊接。在焊接区域的一圈长度为1m、激光输出功率为150W、扫描速率为10m/sec并且总照射长度(200圈)为200m的情况下进行焊接。焊接加工之后的破坏试验表示沿整个长度未检测到剥离，并且获得加强的焊接。
在三维结构的焊接区域中，入射角以及照射面积变化。吸光树脂构件表面处的入射角可变为大约60度。与垂直入射相比，入射角为60度的照射面积加倍。如果使用肋，则期望肋宽具有足够的裕度。肋宽优选为2mm至3mm。肋高优选为0.5mm以上，用于树脂熔化和推动。如果肋的整个高度要被熔化并推动，则肋高优选为1mm以下，以减小照射能量(激光输出功率)。在该情形下，肋高优选为0.5mm至1mm。例如，在肋宽为3mm且肋高为0.5mm的情况下，获得稳定且良好的焊接。
激光束通过透光树脂构件照射到吸光树脂构件。透光树脂构件的上表面还构成光学界面，并反射激光束。当透光树脂构件的上表面处的入射角超过70度时，树脂构件中的入射效率大大降低，因此通常实践上不使用。
图3C示出从透光压力板25输入激光束的模式，透光压力板25经由与透光树脂构件22的上表面形状匹配的弹性透光构件33布置。弹性透光构件33例如由透明硅树脂制成。对于该弹性透光构件，可以参照图1和2以及通过引用结合于此的JP-A-2004-349123的第007段至0013段的公开内容。
图3D示出从多个扫描头31a和31b同时照射多个激光束的模式。扫描头31a和31b可供应来自不同激光源的激光束，或者可供应通过分割来自一个激光源的激光束而获得的激光束。激光束分别分配给通过分割焊接区域而获得的两个或多个部分的相应部分。由于照射区域被分割，因此，待由一个扫描头扫描的每个激光照射区域变窄，从而可以降低最大入射角，并且增大总体激光照射面积。
扫描头与焊接区域形状的结合可采用各种构造。在激光束的宽度相对于焊接区域的宽度较短的情况下，可在焊接区域上设置多条焊线，多条焊线在焊接区域的宽度方向上具有不同位置，并且激光束在每条焊线处照射多次。
如图3E所示，焊接区域27可被分成多条焊线27-1、27-2和27-3。激光束顺序地照射到各焊线。激光束12s在焊接区域27的焊线27-1、27-2和27-3上反复扫描。与上述实施方式类似，在将加工目标组件放置在合适位置之后，同一位置受到激光束的多次照射而从其中待焊接的树脂构件的温度处于初始温度的状态直到其中焊接区域处于熔化状态的状态。
在使用电流镜的焊接加工中，由于激光源固定，因此距激光源的距离可随激光照射位置而变化。焊接区域的法线与激光束之间的角(即入射角)可随着激光照射位置而变化。激光束的照射面积随着入射角而变化。如果进行恒定速率扫描，则每单位时间或每单位面积的入射能量可随位置而变化，因此到达温度可随位置而变化。
为了观察因入射角的差引起的到达温度的差，形成焊接区域宽度为2cm且焊接区域长度为15cm的样品，并且进行试验照射。样品的形状与图1D中所示的形状相似。激光源布置在样品中心上方50cm的位置处，样品表面沿其宽度方向倾斜，以设置0、30和60度的最小入射角，以进行激光束的反复扫描。在透镜与壳体之间夹设热电偶，以测量温度。透镜由PMMA制成，壳体由ASA制成。在激光输出功率为200W且扫描速率为4m/sec时，激光束连续照射20次。在该试验中，焊线每通过一个扫描照射一次，插入大约0.8sec的间隔，以模拟一部分实物的焊接加工。
图5是示出在最小入射角为0、30和60度的情况下，温度随激光照射时间而变化的曲线图。如从该曲线图可见，在最小入射角为0度时，焊接区域的到达温度在最大时大约为190℃，而在最小入射角为60度时，焊接区域的到达温度在最大时仅大约为130℃。可以看出，在入射角变大时，到达温度相对下降。从不同的角度来说，在入射角变大时，到达需要温度所花费的时间延长。
实物的焊接区域通常具有复杂的结构，并且在某些情况下为三维结构。提议在焊接区域中入射角和到达温度可呈现多种变形。在该情形下，可能存在导致产生气泡的局部过分加热或者因加热不足而导致无熔融状态的缺陷焊接。优选的是，抑制待照射到焊接区域的激光束的入射角改变并抑制到达温度变化。本发明人已研究出在使用电流镜的焊接加工中，能够抑制焊接区域中入射角和到达温度的变化的加工目标结构。
图6A和6B示出来自固定激光源的扫描激光束的入射角变化的实施例。图6A是侧视图，图6B是俯视图。用来自固定在位置51处的激光源的激光束照射在x-方向上延伸的条形焊接表面50，位置51与条形焊接表面50在y-方向上隔开40cm，在z-方向上隔开50cm。激光束53以大约39度的入射角到达焊接平面52，当如图6B中所示在水平面观看时，激光束53以直角传播到焊接平面50的位置52，该传播如在图6A中所示为倾斜入射。激光束57以大约53度的入射角到达焊接平面56，当如图6B中所示在水平面观看时，激光束57传播到位置56，位置56与位置52在x-方向上隔开大约50cm。入射角变化较大。现在考虑使焊接平面倾斜。焊接平面在位置56处倾斜成面向激光源51。可实现大约39度的激光束入射角。然后，入射角变为近似等于位置52处的入射角。可以看出，可通过使焊接面在宽度方向上从位置52逐渐向位置56倾斜以面向各激光源，来抑制入射角的变化。当所述位置与位置56进一步间隔开时，入射角进一步增大。
如图6C中所示，在焊接区域中具有最大入射角的位置处，例如焊接平面在宽度方向上倾斜以使入射角降低，以使能量密度最大。在其它位置，焊接平面在宽度方向上倾斜，以实现恒定入射角，或者至少抑制入射角的变化。由于抑制了入射角的变化，因此抑制于入射能量密度的变化，并且可使到达温度统一化。
当焊接平面在朝激光源的方向上倾斜时，入射能量密度增大，并且当焊接平面在远离激光源的方向上倾斜时，入射能量密度减小。通常不允许变化焊接平面在z-方向上的位置。因此焊接平面在宽度方向上倾斜。尽管在上述说明中焊接区域布置在二维平面上，但是该实施方式类似地可应用于三维结构的焊接区域。
考虑到激光束自身的强度分布(例如高斯分布)，在宽度方向上倾斜的焊接区域可以是曲面，而不是平面。该修改可更加有助于照射平面中的温度偏差统一化。
通过倾斜焊接平面，在统一化入射角、入射能量密度和到达温度上可能存在一些限制。
通过根据入射角控制激光束扫描速率，可抑制沿激光扫描方向的到达温度的变化。例如，在入射角变大而每单位面积的入射能量和发热量相对降低的位置处，优选的是，降低扫描速率以增大每单位时间的发热量，以由此统一化激光扫描方向上的温度偏差。该控制可通过图1A中所示的控制设备16进行。
如上所述，响应于当焊接区域的宽度方向与水平面平行时的虚拟入射角，通过使焊接表面在宽度方向上连续倾斜，可抑制焊接区域中入射角变化。在抑制到达温度变化的状态下，还通过控制激光扫描速率，可几乎同时或同步地加热、熔化和焊接整个焊接区域。
当焊接区域进入软化和熔融的状态时，提供可变形性和流动性。
图7A是示出夹设在上下固体状态区域之间的焊接区域的板状熔融状态的平面图。熔融树脂因压力趋于径向延伸，同时填埋间隙，如箭头50和51或箭头52和53所示在宽度方向上(图7A中的上下方向)流向外侧。
如图7B所示，树脂构件21和22混合地熔化，间隙和交界面消失，以允许进行增强的焊接。此时，在宽度方向上排出到焊接区域的两侧的熔融树脂构件形成称作毛刺的排出区域23。不希望形成毛刺，因为会降低树脂模具组件的外观质量。
为了保证结合强度，必须用熔融树脂构件填充间隙并去除间隙。在该情形下，熔融树脂构件一定程度上流向焊接区域的外侧。难以完全抑制毛刺的形成。
如果可在焊接区域的两侧有选择地形成毛刺则存在优选情形。例如，在树脂膜制品需要密封的情况下，如果在树脂模制品的外侧形成毛刺，则可在激光加工中去除该毛刺。因此，不会降低最终模制品的外观质量，并且获得增强的结合。即使在不需要密封的树脂模制品的情形下，如果在树脂模制品的一侧不形成毛刺，则与在允许两侧均形成毛刺的情况相比，可缩短用于去除毛刺的时间。在生产效率方面这也是优选的。如果可限制熔融树脂的流动性，则形成在焊接区域的外侧的毛刺可被限制成仅位于一侧。
通常而言，在包括熔融树脂的液体中，在温度与粘度之间保持负相关。当液体的温度升高时，其粘度减小，当液体温度降低时，其粘度增大。液体的粘度限定为代表液体流动与抵抗流动的阻力之间的关系的比例常数。如果液体具有高粘度，则抵抗液体流动的阻力高，而如果液体具有低粘度，则抵抗液体流动的阻力低。因此在液体的温度与抵抗液体流动的阻力之间满足负相关。因此，保持这样的关系：当液体温度变高/降低时粘度减小/增大，而当粘度减小/增大时，抵抗液体流动的阻力也减小/增大。
通过使用液体的上述一般特性，可以例如通过在焊接区域中形成温度梯度，并且通过在焊接区域中形成粘度和抵抗流动的阻力的偏差，来控制熔融树脂的流动朝具有低阻力的区域流动。
图7C是示出在焊接区域中沿宽度方向(图7C中的x-轴方向)存在温度梯度的状态的示意图。假设例如在焊接区域中沿x-轴正向温度变高，则相应地在x-轴位置方向上粘度下降并且抵抗流动的阻力也下降。当在相互推动的方向上向透镜和壳体施加压力时，如箭头60和61所示，更多的熔融树脂在x-轴正向上朝低阻力区域流动。因此在x-轴正向上可能形成更多的毛刺。
通过以上述方式在焊接区域中沿宽度方向形成温度梯度并形成粘度和抵抗流动的阻力的偏差，可以使熔融树脂在低阻力方向上流动，并且优选在焊接区域的一侧形成毛刺。在下列实施方式中，进行激光束焊接，以根据上述原理优选在焊接区域的一侧形成毛刺。
图8A是示出具有布置在二维平面上的焊接区域的加工目标制品的示意剖视图。由透光树脂制成的透镜22布置在由吸光树脂制成的壳体21上，使两者的焊接区域彼此面对。在该实施例中，用于焊接的肋24形成在壳体的局部上表面上。肋24不是必要的构成元件。透镜22的下表面与形成在壳体21的上表面上的肋24以压力P加压并接触。激光束12s穿过透镜22并照射形成在壳体21上的肋24的上表面。通过驱动电流镜沿肋(焊接区域)扫描照射位置。布置焊接区域的平面由xy平面表示。在图1A中所示的结构中，第一电流镜14进行x-方向扫描，第二电流镜15进行y-方向扫描。
图8B是示出环形(示意地绘制成圆条形)的二维焊接区域27的示意图。在该实施例中，在焊接区域的宽度方向上限定三条焊线，该三条焊线顺序地受到反复的激光束照射。首先，激光束反复照向焊线27a。如图1E的曲线图中所示的温度变化所示，焊线27a被加热，经过软化状态而进入熔融状态，然后在照射结束后允许降低其温度。在该情况下，将不会有效地去除间隙，因为焊线27b和27c仍未被激光束照射，并且呈固相。
紧接着，在焊线27a的温度下降并且焊线27a呈固相之前，向焊线27b反复地照射激光束，以加热并熔化焊线27b。类似地，在焊线27a和27b的温度下降并且焊线27a和27b呈固相之前，向焊线27c反复照射激光束，以加热并熔化焊线27c。
此时，整个焊接区域进入熔融状态。施加压力可以有效地去除间隙。在激光束结束反复照射之后，由于焊线27a和27b的温度因时间的流逝自然冷却而下降，因此焊接区域在温度和粘度上具有偏差。如从图8B中示意地示出的曲线图可见，焊接区域中的温度分布从焊线27a至焊线27c为阶梯式梯度。加压的熔融树脂将流向具有较高温度和较低阻力的焊线27c，更多的熔融树脂将排出焊接区域的外周。
图8C是示出在每条焊线处平均温度的时间变化的曲线图。具体而言，激光束的反复照射使得温度重复升降，以逐渐加热各焊线。在该曲线图中，示出平均温度变化(通过激光束反复照射而反复的温度升降的平均)。以Tg表示熔化壳体所需要的温度(玻璃化转变温度)。
从时间t10至t11，熔化线27a通过激光束的反复照射而被逐渐加热，到达比玻璃化转变温度Tg足够高的温度并进入熔融状态。在时间t11处，激光束的反复照射从焊线27a转到焊线27b，焊线27a的温度因自然冷却而开始下降。此时，由于焊线27b和27c不照射激光束，因此将不会有效地去除间隙。
从时间t11至t12，焊线27b通过激光束的反复照射而逐渐被加热并熔化。在时间t12处，激光束的反复照射从焊线27a转到焊线27b，焊线27a的温度因自然冷却而开始下降。此时，由于焊线27c不照射激光束，因此将不会有效地去除间隙。
从时间t12至t13，焊线27c通过激光束的反复照射而被加热。在时间t13处，焊线27c到达玻璃化转变温度Tg，并且在时间t13之后也被加热。由于整个区域进入熔化状态，因此两个树脂构件熔化在一起，因此，通过施加压力而可以有效地去除间隙。
从时间t14至t15，如从图8B中示意地示出的曲线图可见，通过时移激光束照射形成从焊线27a到焊线27c顺序呈高温的阶梯温度梯度。基于温度、粘度与液体阻力之间的关系，加压熔融树脂朝具有高温和低阻力的焊线27c流动，更多的熔融树脂排出焊接区域的外周。在时间t15之后，由于自然冷却，温度顺序地以从焊线27a至焊线27c的顺序变得比玻璃化转变温度低，而使各焊线为固相。在固相下，将不发生树脂的变形和流动，排出焊接区域外部的熔融树脂固化而形成毛刺。在最终状态下，焊接区域稳固地结合，并且优选在焊接区域的一侧形成毛刺。
如上所述，激光束以高速扫描，以加热并熔化焊线，在加热并熔化的焊线降低温度而变为固相之前，激光束照射位置顺序地移动到未用激光束照射的另一条焊线。整个焊接区域被同步地加热并熔化，并且因激光束照射差而在焊接区域中形成温度梯度。即，在焊接区域的宽度方向上限定沿焊接区域的延伸方向的多条焊线，并且相应的焊线被赋予加热、熔化和冷却的相应时间(定时)差，以在焊接区域的宽度方向上形成温度梯度。因此粘度与抵抗熔融树脂的流动的阻力形成偏差。因此可以在焊接区域中向较高温度侧排出更多的熔融树脂，同时可以有效地去除间隙并获得增强的结合。
本发明人通过形成样品作为试验件而进行试验照射。样品的肋宽为3mm，肋长为15cm。透镜由PMMA制成，壳体由ASA制成。通过在肋的宽度上设置三条焊线，并且以输出功率为190W、扫描速率为10m/sec的激光多次扫描各线的中心，来进行焊接。照射激光束的直径设定为2mm和3mm。在该试验照射中，插入大约0.1秒的间隔，以模拟一部分实物的焊接加工。焊接加工之后的破坏试验表示在沿整个长度的焊接区域中未观察到裂缝的破坏模式，因此获得增强焊接。观察到在试验件的外侧上形成毛刺。
在该试验照射中，在具有3mm肋宽的焊接区域上等距地设置三条焊线。由于激光束直径为2mm至3mm，因此靠近焊线的边界的区域被双重加热。激光束具有通常的强度分布(例如高斯分布)。在靠近焊线的边界的区域中，照射能量密度比激光束中央低，因此，温度升高较低。在靠近焊线的边界的区域中的双重照射将相对地补偿因能量密度比激光束中心低造成的加热不足。靠近焊线的边界的温度呈现相邻焊线的中心处的温度之间的中间温度。整个焊接区域中的温度梯度可以不是如图8B中所示的阶梯状，而实际上是渐进且连续的温度梯度。
在该实施方式中，尽管使用二维焊接区域，但该实施方式还可应用于三维焊接区域。
当将下列方法结合到该实施方式时，促进焊接区域中的毛刺的选择性形成。
例如，对于在焊接区域中形成毛刺一侧上具有更高温度的焊线，激光束的扫描速率可下降，以提高吸光树脂每单位面积的吸光量和发热量，并且提升焊接区域中的温度梯度。图1A中所示的控制设备16可进行激光束的扫描速率控制。
还存在一种通过单调地变化焊接区域中焊线的宽度来提升焊接区域中温度梯度的方法。较窄的焊线将被加热至较高的温度。如果采用这些方法，则激光束可不扫描成使得相应的焊线被顺序地加热到熔融状态，而是可以扫描成使得相应的焊线同时被照射，以同时被加热成具有由每单位面积的发热量差给出的温度梯度。
图9是示出熔融状态中的焊接区域的一部分的示意图。箭头表示待由激光束反复照射的轨迹或焊线。焊线宽度朝毛刺形成侧单调减小(每单位面积的焊线数量单调增加)。激光束直径随着焊线宽度而顺序减小。例如，通过顺序地朝毛刺形成侧移动而进行每条焊线的加热和熔化。由于毛刺形成侧的每单位面积的发热量变得较大，因此，如图9中右侧的示意曲线图所示，可以促进焊接区域中的温度梯度，在该情形下，在焊接区域宽度方向上形成温度梯度的方法可不伴随有通过利用加热/冷却相应焊线的时间(正时)差形成温度梯度。例如，激光束可从一侧到另一侧顺序地照射焊线，并且该顺序可重复，以加热并熔化整个焊接区域。各焊线被均匀地加热并熔化。由于焊线宽度朝毛刺形成侧单调递减，因此，毛刺形成侧上每单位面积的发热量变得较大，可在焊接区域宽度方向上形成温度梯度。
通过同时照射具有不同能量密度的激光束，可以促进焊接区域中的温度梯度。
以上已描述了多个实施方式。本发明不局限于这些实施方式。例如，透光树脂构件与吸光树脂构件的结合不限于透镜和壳体。可形成用于例如宝石之类的小精致产品的陈列柜。可以是其它各种应用。本领域技术人员应明白，可以进行各种变更、替换、改良、组合等。

Claims (22)

1.一种用于制造树脂模具组件的方法，该方法包括下列步骤：
将透光树脂构件布置在吸光树脂构件上，使所述透光树脂构件的第一焊接区域面向所述吸光树脂构件的第二焊接区域；
在所述透光树脂构件与所述吸光树脂构件之间施加压力，以使所述透光树脂构件的所述第一焊接区域与所述吸光树脂构件的所述第二焊接区域在相互面对的方向上挤压接触；并且
使用包括能够调节入射激光束的焦距的调焦光学系统以及布置在所述调焦光学系统的下游并且能够二维扫描入射激光束的电流镜的光学系统，通过所述透光树脂构件在所述吸光树脂构件的所述第二焊接区域上施加激光束，同时借助所述调焦光学系统调节所述激光束相对于所述第二焊接区域的焦距，并借助所述电流镜在所述第二焊接区域的整个面积上二维扫描所述激光束，以在所述第二焊接区域上反复照射所述激光束，从而同步地从环境温度加热并熔化整个所述第一焊接区域和第二焊接区域，并且焊接所述透光树脂构件和所述吸光树脂构件。
2.根据权利要求1所述的用于制造树脂模具组件的方法，其中，所述激光束的焦点从所述第一焊接区域和所述第二焊接区域之间的交界面散焦。
3.根据权利要求1所述的用于制造树脂模具组件的方法，其中，在所述扫描期间，在所述第二焊接区域上限定多条焊线，并且沿相应的焊线进行所述扫描。
4.根据权利要求1所述的用于制造树脂模具组件的方法，其中，所述透光树脂构件为透镜，所述吸光树脂构件为壳体。
5.根据权利要求1所述的用于制造树脂模具组件的方法，其中，在所述第二焊接区域中的同一位置上用所述激光束多次照射所述吸光树脂构件，直到到达玻璃化转变温度时为止，并且用所述激光束进一步照射多次，直到到达熔化状态时为止。
6.根据权利要求1所述的用于制造树脂模具组件的方法，其中，所述第一焊接区域与所述第二焊接区域之间的接触面具有三维结构，所述激光束在所述接触面上的入射角随着位置而变化，所述激光束的扫描速率随着所述位置而变化，以平均化加热温度。
7.根据权利要求1所述的用于制造树脂模具组件的方法，其中，所述激光束在与所述第二焊接区域接触的虚拟平面上的入射角随着位置而变化，并且所述激光束的扫描速率变化，以平均化加热温度。
8.根据权利要求1所述的用于制造树脂模具组件的方法，其中，所述透光树脂构件在与所述吸光树脂构件相对的表面上具有肋，所述肋的宽度为2mm至3mm，高度为0.5mm至1mm。
9.根据权利要求1所述的用于制造树脂模具组件的方法，其中，所述第一焊接区域与所述第二焊接区域之间的接触面沿宽度方向具有倾角。
10.根据权利要求2所述的用于制造树脂模具组件的方法，其中：所述第二焊接区域具有环形形状，在宽度方向，沿所述第二焊接区域的环形延伸方向限定多条焊线；在所述激光束被反复照射在所述第二焊接区域上的状态下，在所述第二焊接区域的宽度方向上形成温度梯度。
11.根据权利要求10所述的用于制造树脂模具组件的方法，其中，通过控制所述激光束的照射定时形成所述温度梯度。
12.根据权利要求10所述的用于制造树脂模具组件的方法，其中，所述多条焊线限定为具有等宽度，所述激光束反复地照射在每个所述焊线上，以从所述第二焊接区域的一侧向另一侧顺序地加热并熔化所述相应的焊线。
13.根据权利要求10所述的用于制造树脂模具组件的方法，其中，所述激光束的能量密度对于所述多条焊线中的每个发生变化。
14.根据权利要求10所述的用于制造树脂模具组件的方法，其中，所述多条焊线的宽度从一侧向另一侧单调减小。
15.根据权利要求10所述的用于制造树脂模具组件的方法，其中，通过扫描所述激光束而从所述一侧上的一条焊线到所述另一侧上的另一条焊线顺序地进行加热并熔化，以加热并熔化整个所述第一焊接区域和第二焊接区域。
16.根据权利要求14所述的用于制造树脂模具组件的方法，其中，所述激光束照射所述一侧上的一条焊线，并且朝向所述另一侧上的另一条焊线顺序地照射所述焊线，反复地进行该照射顺序，以加热并熔化整个所述第一焊接区域和第二焊接区域。
17.根据权利要求13所述的用于制造树脂模具组件的方法，其中，反复照射所述焊线的所述激光束的扫描速率对于每个所述焊线不同。
18.根据权利要求10所述的用于制造树脂模具组件的方法，其中，所述激光束的直径比所述焊线的宽度大一至三倍。
19.一种用于制造树脂模具组件的方法，该方法包括下列步骤：
将透光树脂构件布置在吸光树脂构件上，使所述透光树脂构件的第一焊接区域面向所述吸光树脂构件的第二焊接区域；
在所述透光树脂构件与所述吸光树脂构件之间施加压力，以使所述透光树脂构件的所述第一焊接区域与所述吸光树脂构件的所述第二焊接区域在相互面对的方向上挤压接触；并且
通过所述透光树脂构件在所述吸光树脂构件的所述第二焊接区域的不同部分上施加多个激光束，并在所述第二焊接区域的整个面积上扫描整个所述激光束，以在所述第二焊接区域上反复照射所述激光束，从而同步加热并熔化整个所述第一焊接区域和第二焊接区域，并且焊接所述透光树脂构件和所述吸光树脂构件。
20.根据权利要求19所述的用于制造树脂模具组件的方法，其中，所述焊接区域沿延伸方向被分成多个部分，所述多个激光束分别分配到所述部分，并且被分别扫描在所分配的所述部分上。
21.根据权利要求19所述的用于制造树脂模具组件的方法，其中，所述焊接区域被分成沿宽度方向排列的多条焊线，所述多个激光束具有不同光学强度，并且照射所述多条焊线，以在所述第二焊接区域的宽度方向上形成温度梯度。
22.根据权利要求19所述的用于制造树脂模具组件的方法，其中，对于所述多个激光束中的每个激光束，使用包括能够调节入射激光束的焦距的调焦光学系统以及布置在所述调焦光学系统的下游并且能够二维扫描入射激光束的电流镜的光学系统，通过相关的所述调焦光学系统调节每个所述激光束相对于所述第二焊接区域的焦距，并且二维扫描每个所述激光束。
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