CN102131632A - 用于使树脂和金属接合的方法和装置 - Google Patents

用于使树脂和金属接合的方法和装置 Download PDF

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Publication number
CN102131632A
CN102131632A CN2009801325741A CN200980132574A CN102131632A CN 102131632 A CN102131632 A CN 102131632A CN 2009801325741 A CN2009801325741 A CN 2009801325741A CN 200980132574 A CN200980132574 A CN 200980132574A CN 102131632 A CN102131632 A CN 102131632A
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Prior art keywords
resin
component element
resin component
metal
hardware
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CN2009801325741A
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CN102131632B (zh
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杉山徹
柴田义范
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Toyota Motor Corp
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Toyota Motor Corp
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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
    • 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
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/44—Joining a heated non plastics element to a plastics element
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1677—Laser beams making use of an absorber or impact modifier
    • B29C65/1683—Laser beams making use of an absorber or impact modifier coated on the article
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/3656—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the type of elements heated by induction which remain in the joint being a layer of a multilayer part to be joined, e.g. for joining plastic-metal laminates
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C65/3672—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the composition of the elements heated by induction which remain in the joint
    • B29C65/3676—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the composition of the elements heated by induction which remain in the joint being metallic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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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    • B29C66/022—Mechanical pre-treatments, e.g. reshaping
    • B29C66/0224—Mechanical pre-treatments, e.g. reshaping with removal of material
    • B29C66/02245—Abrading, e.g. grinding, sanding, sandblasting or scraping
    • 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
    • B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
    • B29C66/028—Non-mechanical surface pre-treatments, i.e. by flame treatment, electric discharge treatment, plasma treatment, wave energy or particle radiation
    • 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
    • B29C66/112—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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    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot 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
    • B29C66/303—Particular design of joint configurations the joint involving an anchoring effect
    • B29C66/3032—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined
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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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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
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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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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/91931—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 the fusion temperature or melting point of the material of one of the parts to be joined
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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
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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    • B29C65/3604—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the type of elements heated by induction which remain in the joint
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract

通过加热使树脂构件(4)和金属构件(3)接合的方法和装置，其中通过将树脂构件和金属构件的接合界面加热到在等于或高于所述树脂构件的分解温度并且低于在所述树脂构件中产生气泡的温度的范围内的温度，并且通过将所述树脂构件的在其与所述金属构件的接合表面的相反侧的表面冷却到低于所述树脂构件的熔点的温度，来执行所述树脂构件和所述金属构件的接合。

Description

用于使树脂和金属接合的方法和装置
技术领域
本发明涉及通过加热使树脂和金属接合的接合方法和接合装置。
背景技术
通常通过使用粘合剂来将树脂构件和金属构件接合在一起，但是为了简化接合过程并且遵照挥发性有机化合物(VOC)规则，在金属构件和树脂构件的接合表面上形成物理凹部和凸部，或者通过执行诸如酸处理或碱处理或者底漆处理的表面处理来修正化学官能团，或者通过在金属构件和树脂构件的接合表面上实施热塑性树脂的夹物模压(insert molding)，来获得金属和树脂的接合体。
在通过如上所述的、其中金属构件和树脂构件的接合表面经受了表面处理的工艺来将金属构件和树脂构件接合在一起的情况下，尽管未使用粘合剂，但是使用了诸如酸、碱或底漆处理剂的大量表面处理剂，因此，当用过的表面处理剂被丢弃时，产生了环境负荷。另外，表面处理后的金属构件必须被清洗和干燥，并且对于清洗和干燥操作需要较长时间。结果，前述工艺不适用于需要高生产率的部件，诸如汽车用部件等。与通过在金属构件上夹物模压热塑性树脂来接合金属构件和树脂构件的工艺相关的问题是：对接合体的形状产生限制。
因此，例如，公开号为5-185521的日本专利申请(JP-A-5-185521)描述了一种在短期内通过简单工艺来使树脂构件和金属构件接合的方法，所述方法未使用粘合剂或者表面处理剂，并且未产生环境负荷，其中通过加热和熔化将树脂构件接合到金属构件上。
如上所述，在将树脂构件加热到熔化温度或者软化温度的情况下，软化后的树脂构件根据金属构件表面的凹部和凸部变形，并且通过由于这种变形展现的固着效应使两个构件接合，但是仅仅通过固着效应不能在接合中获得足够的接合强度。此外，通过炉内的热氛围或者利用加热器加热树脂构件，但是如果加热温度太高，则会在树脂内产生气泡，并且这些气泡使得在接合之后在树脂构件中产生裂纹。另外，在整个树脂构件被加热的情况下，树脂构件完全熔化，并且树脂构件的外表面的设计特性也损失了。由此产生的问题是限制了树脂构件和金属构件接合的应用范围。
发明内容
本发明提供了用于树脂和金属的接合方法和接合装置，通过所述接合方法和所述接合装置，利用简单工艺在短期内将树脂构件和金属构件接合，不会产生环境负荷，能够获得足够的接合强度，并且不降低树脂构件的外表面的设计特性。
本发明的第一方面涉及通过加热使树脂和金属接合的接合方法。通过这种接合方法，通过将所述树脂和所述金属的接合界面加热到在等于或高于所述树脂的分解温度并且低于在所述树脂中产生气泡的温度的范围内的温度，来执行所述树脂和所述金属的接合。利用这种接合方法，未使用表面处理剂，在短时间内可获得必要且足够的接合强度，并且可减小在使树脂和金属接合的过程中的环境负荷。进一步，在树脂和金属接合之后，能够防止由在树脂和金属的接合界面处的气泡引起的裂纹的产生，并且能够确保树脂和金属的接合强度。
在根据前述方面的接合方法中，从所述金属的在其与所述树脂的接合表面的相反侧的表面加热所述树脂和金属的接合界面，并且将所述树脂的在其与所述金属的接合表面的相反侧的表面冷却到低于所述树脂的熔点的温度。利用这种接合方法，未使用表面处理剂，在短时间内可获得必要且足够的接合强度，并且可减小在使树脂和金属接合的过程中的环境负荷。进一步，由于执行了所述树脂和金属的接合，在所述树脂和金属的接合期间防止所述树脂热变形的同时，不会降低所述树脂和金属的接合体在所述树脂侧的外表面的设计特性，并且可增大接合体的产品价值。
在根据前述方面的接合方法中，通过将薄膜插入所述树脂和金属的所述界面中并且从所述树脂的在其与所述金属的接合表面的相反侧的表面高频加热所述薄膜，执行所述树脂和金属的所述接合，所述薄膜具有比所述金属的电阻高的电阻。结果，即使在所述金属由具有高导热系数和低电阻的材料构成时，也可增大输入到所述金属和树脂的接合区的热量的效率，可以通过简单工艺且在短时间内充分加热所述金属和树脂的接合界面以用于接合，并且可获得足够的接合强度。
进一步，在根据前述方面的接合方法中，将具有比金属的激光反射率低的激光反射率的薄膜插入所述树脂和金属的界面中，所述树脂由能够传递激光辐射的材料构成，并且通过从所述树脂的在其与所述金属的接合表面的相反侧的表面朝向所述薄膜发射激光辐射并且加热所述薄膜，执行所述树脂和金属的接合。结果，即使在所述金属具有激光辐射的高反射率时，也可增大输入到所述金属和树脂的接合区的热量的效率，通过简单工艺且在短时间内可充分加热所述金属和树脂的接合界面以用于接合，并且可获得足够的接合强度。
进一步，在根据前述方面的接合方法中，加热后的树脂可以渗入的凹部形成在所述金属的在所述树脂和所述金属的接合区周围的区域内。结果，软化后的树脂渗入到所述凹部内，并且在使所述金属和树脂接合时产生固着效应，从而使得能够增大接合后所述金属和树脂的接合强度。
本发明的第二方面涉及通过加热使树脂和金属接合时使用的接合装置。所述接合装置包括加热工具和冷却工具，所述加热工具从所述金属的在其与所述树脂的接合表面的相反侧的表面加热所述树脂和所述金属的接合界面，并且所述冷却工具将所述树脂的在其与所述金属的接合表面的相反侧的表面冷却到低于所述树脂的熔点的温度。利用这种构造，在短时间内可获得必要且足够的接合强度，并且无需使用表面处理剂可减小在使所述树脂和金属接合的过程中的环境负荷。进一步，由于执行了所述树脂和金属的接合，因此在所述树脂和金属的接合期间，防止所述树脂热变形的同时，可增大接合体的产品价值，无需降低所述树脂和金属的接合体在所述树脂侧的外表面的设计特性。
进一步，在根据前述方面的接合装置中，加热工具将所述树脂和金属的接合界面加热到在等于或高于所述树脂的分解温度并且低于在所述树脂中产生气泡的温度的范围内的温度。利用所述构造，未使用表面处理剂，在短时间内可获得必要且足够的接合强度，并且可减小在接合所述树脂和金属的过程中的环境负荷。进一步，能够防止由在所述树脂和金属的接合界面处的气泡引起的裂纹的产生，并且能够确保所述树脂和金属的接合强度。
根据本发明，未使用表面处理剂，在短时间内可获得必要且足够的接合强度，并且可减小在接合所述树脂和金属的过程中的环境负荷。
附图说明
从下面参照附图对示例实施例的描述中，本发明的前述的和进一步的特征和优点将变得显而易见，其中相同的数字用于表示相同的零件，并且其中：
图1为示出如何通过使用包括加热体和冷却体的接合装置将金属构件和树脂构件接合在一起的侧视图；
图2示出了树脂构件和金属构件的接合表面的温度和加热时间之间的关系；
图3为将加热体和冷却体形成为与点焊机的焊枪的形状相似的形状的接合装置的侧视图；
图4为将加热体和冷却体构造为辊子构件的接合装置的侧视图；
图5为示出狭缝形成在金属构件和树脂构件的接合区的周边上的金属构件的立体图；
图6为示出将狭缝形成在金属构件和树脂构件的接合区的周边上的金属构件中的热传递状态的侧剖视图；
图7为将狭缝形成在金属构件和树脂构件的接合区的周边上的金属构件的平面图；
图8为示出软化后的树脂构件渗入到形成在金属构件中的狭缝中的状态的侧剖视图；
图9为显示开设在与树脂构件的接合表面的相反侧的表面处的凹槽形成在金属构件和树脂构件的接合区的周边上的金属构件的立体图；
图10为显示开设在与树脂构件的接合表面的相反侧的表面处的凹槽形成在金属构件和树脂构件的接合区的周边上的金属构件的侧剖视图；
图11为显示开设在与树脂构件的接合表面的相反侧的表面处的凹槽和开设在与树脂构件的接合表面处的凹槽均形成在金属构件和树脂构件的接合区的周边上的金属构件的侧剖视图；
图12为显示开设在与树脂构件的接合表面处的凹槽形成在金属构件和树脂构件的接合区的周边上的金属构件的立体图；
图13为显示开设在与树脂构件的接合表面处的凹槽形成在金属构件和树脂构件的接合区的周边上的金属构件的侧剖视图；
图14为显示如何使用高频加热装置作为加热体来加热金属构件和树脂构件的接合界面的侧剖视图；以及
图15为显示如何使用激光辐射作为加热体来加热金属构件和树脂构件的接合界面的侧剖视图。
具体实施方式
下面将参照附图描述本发明的实施例。
如图1所示，在将树脂构件4和金属构件3接合在一起的本实施例的接合方法中，在树脂构件4和金属构件3堆叠的状态下，通过利用作为加热工具的加热体1将树脂构件4和金属构件3的接合界面加热到预定温度，来使树脂构件4和金属构件3接合。
更具体地说，例如，通过使加热体1接触金属构件3的在其与树脂构件4接合表面的相反侧的表面，来加热树脂构件4和金属构件3的接合界面。进一步，实施利用加热体1的加热，以使树脂构件4与金属构件3的接合表面5呈现在等于或高于树脂构件4的分解温度并且低于在树脂构件4中产生气泡的温度的范围内的温度。
在这种情况下，如图2所示，树脂构件4的分解温度tb高于树脂构件4的熔点ta，并且在树脂构件4中产生气泡的温度tc高于树脂构件4的分解温度tb。进一步，加热体1的温度td高于在树脂构件4中产生气泡的温度tc(换句话说，(加热体1的温度td)＞(在树脂构件4中产生气泡的温度tc)＞(树脂构件4的分解温度tb)＞(树脂构件4的熔点ta))。当使树脂构件4和金属构件3接合时，在预定的时间段ΔT，通过将树脂构件4和金属构件3的接合界面，严格地说，将树脂构件4的接合表面5保持在等于或高于树脂构件4的分解温度并且低于在树脂构件4中产生气泡的温度的范围内的温度(此范围包括在图2中的阴影部分中)，来执行树脂构件4和金属构件3的接合。
同时，当以上述方式用加热体1执行加热时，作为冷却工具的冷却体2接触树脂构件4的在接合表面5的相反侧的表面，并且树脂构件4的在接合表面5的相反侧的表面被冷却到低于树脂构件4的熔点的温度。
换句话说，在树脂构件4和金属构件3堆叠的情况下，通过将与金属构件3的接合界面接触的树脂构件4的接合表面5加热到在等于或高于树脂构件4的分解温度并且低于在树脂构件4中产生气泡的温度的范围内的温度、并且将树脂构件4的在接合表面5的相反侧的表面冷却到低于树脂构件4的熔点的温度，来执行树脂构件4和金属构件3的接合。
在通过将树脂构件4加热到熔点ta来执行树脂构件4和金属构件3的接合的情况下，仅仅因为已经达到熔化温度且已软化的树脂构件4的接合表面5沿着金属构件3的接合表面的峰和谷变形并且展示出了固着效应，因此所述两个构件被接合。相反，如上所述，在将树脂构件4的接合表面5加热到等于或高于树脂构件4的分解温度的温度时，接合表面5处的树脂构件4分解，并且在接合表面5处形成熔合活性基(fusion active group)。通过分子间力将在树脂构件4的接合表面5处产生的熔合活性基结合到金属构件3与树脂构件4的接合表面上，并且除了利用在树脂构件4和金属构件3的接合界面上的固着效应的接合之外，还实施了利用熔合活性基的分子间力的接合，从而能够获得高的接合强度。
由此利用接合装置实施接合，所述接合装置包括加热体1和冷却体2，所述加热体1从金属构件3的在其与树脂构件4的接合表面的相反侧的表面加热树脂构件4和金属构件3的所述接合界面，所述冷却体2将树脂构件4的在其与所述金属构件3的接合表面5的相反侧的表面冷却到低于树脂构件4的熔点的温度。
换句话说，由于通过将树脂构件4的接合表面5加热到在等于或高于树脂构件4的分解温度并且低于在树脂构件4中产生气泡的温度的范围内的温度来使树脂构件4和金属构件3接合，既没有使用粘合剂，也没有使用诸如酸、碱和底漆处理剂的表面处理剂，因此能够在短时间内获得必要且充足的接合强度，并且能够减小在使树脂构件4和金属构件3接合过程中的环境负荷。进一步，由于树脂构件4的接合表面5的加热温度低于在树脂构件4中产生气泡的温度，因此在树脂构件4的接合表面5处没有因为加热而产生气泡，故能够防止由在树脂构件4和金属构件3的接合界面处的气泡引起的裂纹的产生，并且在树脂构件4和金属构件3已经接合之后，能够确保树脂构件4和金属构件3的接合强度。
另外，当使树脂构件4和金属构件3接合时，将树脂构件4的在接合表面5的相反侧的表面冷却到低于树脂构件4的熔点的温度。因此，此表面不会因为加热而变形。由于能够防止树脂构件4在树脂构件4和金属构件3接合期间的热变形，因此不会降低树脂构件4和金属构件3的接合体的在树脂构件4侧的外表面的设计特性，并且能够增大接合体的产品价值。
例如，各种铁金属、不锈钢、铝材料(包括铝合金)、镁材料(包括镁合金)、以及铜材料(包括铜合金)都能够用作构成金属构件3的材料，但是这个列举不是限定，也可使用其它的金属材料。
例如，尼龙树脂、聚酯树脂、丙烯腈丁二烯苯乙烯(ABS)树脂、以及通用的其它热塑性树脂、通用的工程塑料、超级工程塑料和热塑性弹性体都可用作构成树脂构件4的材料。可将诸如能够增加机械强度等的碳化纤维、玻璃纤维、滑石、云母和碳酸钙的填料混合到树脂构件4中。
在树脂构件4由完全无官能团的非极性树脂构成的情况下，在使树脂构件4的接合表面5受到未使用诸如酸、碱或底漆处理剂的表面处理剂的、诸如等离子处理或电晕处理的典型干燥表面处理之后，可实施树脂构件4和金属构件3的接合。通过在执行干燥表面处理之后使树脂构件4和金属构件3如此接合，能够通过具有低的环境负荷的表面处理方法将熔合活性基引入到接合表面5上并且能够增大接合强度。
此外，在树脂构件4由完全无官能团的非极性树脂构成的情况下，优选地在通过使用诸如砂纸的抛光工具对金属构件3与树脂构件4的接合表面进行粗加工或者通过电子束加工或激光加工在金属构件3与树脂构件4的接合表面上形成峰和谷之后，实施树脂构件4和金属构件3的接合。由此在给金属构件3与树脂构件4的接合表面提供粗糙度或峰和谷的情况下，加热后的树脂构件4能够渗入到金属构件3的接合表面中并且展现出固着效应。
进一步，加热体1可由高温物质(固体、液体或气体)构成并且能够被构造为通过使所述高温物质接触金属构件3的在其与树脂构件4的接合表面的相反侧的表面来执行对接合表面5的加热，所述高温物质能够将树脂构件4的接合表面5加热到在等于或高于树脂构件4的分解温度并且低于在树脂构件4中产生气泡的温度的范围内的温度。此外，加热体1可被构成为例如通过电阻加热、高频、红外线辐射或激光辐射来加热接合表面5，或者通过使用由振动或超声波产生的摩擦热来加热接合表面5。这些示例并非限制，并且也可以使用其它的加热方式。
冷却体2可由低温物质(固体、液体和气体)构成，所述低温物质能够将树脂构件4的在其接合表面5的相反侧的表面冷却到低于树脂构件4的熔点的温度，但是这种构造并非限制，也可以使用其它的冷却体。
如图3所示，下面将说明一个实施例，其中，通过使用作为加热体1和冷却体2的杆状构件、使杆状加热体1与金属构件3的在其与树脂构件4的接合表面的相反侧的表面接触来实施加热、并且同样地使杆状冷却体2与树脂构件4的在接合表面5的相反侧的表面接触来实施冷却，使金属构件3和树脂构件4接合。
本实施例的加热体1和冷却体2形成了与点焊机的焊枪的形状相似的形状。更具体地说，加热体1和冷却体2为大致圆柱形柱状构件，其中加热体1和冷却体2各自在接触金属构件3和树脂构件4的那一侧的端部是锥形的，并且在金属构件3和树脂构件4堆叠的状态下，将这些圆柱形柱状构件配置在金属构件3和树脂构件4的两侧上。将加热体1抵压在金属构件3上，将冷却体2抵压在树脂构件4上，并且在金属构件3和树脂构件4堆叠的状态下，将金属构件3和树脂构件4抵压在一起。结果，通过来自加热体1的热量使树脂构件4的接合表面5熔化并且被分解，从而使树脂构件4接合到金属构件3上。在这种情况下，树脂构件4的接触冷却体2的表面由冷却体2冷却，并且因此防止所述表面热变形。由于加热体1和冷却体2形成了与点焊机的焊枪的形状相似的形状，因此可将点焊机的线路和系统用于接合金属构件3和树脂构件4的过程中。
进一步，如图4所示，加热体1和冷却体2可由辊子构件构成。在金属构件3和树脂构件4的堆叠状态下，由辊子构件构成的加热体1和冷却体2彼此相对配置在等于或略小于金属构件3和树脂构件4的厚度的距离处。
通过在彼此相对配置的加热体1和冷却体2之间输送处于堆叠状态的金属构件3和树脂构件4，并且通过加热体1和冷却体2挤压处于堆叠状态的金属构件3和树脂构件4，树脂构件4的接合表面5通过加热体1的热量被熔化且分解，从而使金属构件3和树脂构件4接合在一起。在这种情况下，树脂构件4的与冷却体2接触的表面由冷却体2冷却，并且因此防止所述表面热变形。当执行金属构件3和树脂构件4的接合时，在辊子状加热体1和冷却体2之间输送的金属构件3和树脂构件4通过加热体1和冷却体2的旋转而被相继运送，从而使得像缝焊一样将金属构件3和树脂构件4连续地接合。
金属构件3可具有下述的构造。由此，如图5至图7所示，狭缝(凹部)3a可以形成在金属构件3和树脂构件4的接合区6的周边上的金属构件3中。狭缝3a在金属构件3的与树脂构件4的接合方向上穿过所述金属构件3，并且所述狭缝3a形成在接合区6的周边上的多个位置中。
如图6所示，在金属构件3中形成狭缝3a的部分是凹部。因此，在金属构件3的将狭缝3a夹在中间的两侧之间(在狭缝3a的内侧上的区域和狭缝外侧的区域之间)的热传递被防止。因此，能够防止通过金属构件3从加热体1供给到金属构件3和树脂构件4的接合界面的热量在接合区6的平面方向上扩散到外面，并且所述接合区6能够被有效地加热。进一步，由于热量不会传输到狭缝3a的外面，因此不会实施金属构件3和树脂构件4的接合，从而能够以良好的精度控制接合区6。
在树脂构件4的接合表面5处，由于树脂构件4在比接合区6略宽的区中熔化，因此熔化且软化后的树脂构件4便渗入到狭缝3a中，如图8所示。由此，在树脂构件4渗入到金属构件3的狭缝3a内的部分中产生了固着效应，并且因此，在接合之后金属构件3和树脂构件4的接合强度被增大。
因此，通过在金属构件3中的接合区6的周边上形成狭缝3a，能够禁止金属构件3的在狭缝3a的两侧上的部分之间的热量传输，并且防止经由金属构件3从加热体1供给到金属构件3和树脂构件4的接合界面的热量在接合区6的平面方向上扩散到外面(见图6)。
如图7所示，狭缝3a被形成为覆盖接合区6的周边上的整个区，但接合区6的周边被覆盖的比率可适当改变。因此，由狭缝3a覆盖的区能够相应地被适当确定到禁止传输至接合区6的热量在平面方向上扩散的程度。此外，形成在金属构件3中的狭缝3a可利用切削工具切割或通过例如冲孔的机械加工形成，并且所述狭缝3a也可通过使用激光或电子束的加工形成。
如图9和图10所示，代替在金属构件3中形成上述的狭缝3a，也可以形成凹槽3b，作为防止热量传输到接合区6的外面的结构。凹槽3b由金属构件3的在其与树脂构件4的接合表面的相反侧上的表面朝向接合界面侧形成。换句话说，凹槽3b开设在金属构件3的在其与树脂构件4的接合表面的相反侧上的表面上，并且所述凹槽3b是封闭的且具有在金属构件3与树脂构件4的接合界面侧上的底部。
与狭缝3a相似，凹槽3b形状在接合区6的周边上的多个位置中，并且能够防止通过金属构件3从加热体1供给到金属构件3和树脂构件4的接合界面的热量在接合区6的平面方向上扩散到外面。在使凹槽3b形成为禁止传输至接合区6的热量在平面方向上扩散到外面的构造的情况下，底部在金属构件3和树脂构件4的接合界面侧形成于凹槽3b中，并且凹槽3b不会像前述的狭缝3a一样穿过金属构件3。因此，通过与狭缝3a形成在金属构件3中的情况下的刚性相比，金属构件3的刚性增大了。
如图11所示，凹槽3c和凹槽3d也可分别形成在金属构件3与树脂构件4的接合界面侧上和所述接合界面侧的相反侧的表面侧上，作为防止热量传输至接合区6的外面的结构。凹槽3c开设在金属构件3与树脂构件4的接合表面上，并且所述凹槽3c具有在金属构件3的厚度方向上的中间部分内的底部。凹槽3d开设在接合界面的相反侧上的表面上，并且所述凹槽3d具有在金属构件3的厚度方向上的中间部分内的底部。凹槽3c和凹槽3d配置在金属构件3的平面方向上的大致相同的位置，并且凹槽3c与凹槽3d共享底部。
进一步，与狭缝3a相似，凹槽3c和3d形成在接合区6的周边上的多个位置中，并且能够防止通过金属构件3从加热体1供给到金属构件3和树脂构件4的接合界面的热量在接合区6的平面方向扩散到外面。因此，在凹槽3c和3d形成为禁止传输到接合区6的热量在平面方向上扩散到外面的构造的情况下，每对凹槽3c和3d的底部都在金属构件3的凹槽3c和凹槽3d之间形成，并且凹槽3c和3d不像前述的狭缝3a一样穿过金属构件3。因此，通过与狭缝3a形成在金属构件3中的情况下的刚性相比，金属构件3的刚性增大了。此外，熔化且软化后的树脂构件4渗入到凹槽3c内，从而在树脂构件4渗入到金属构件3的凹槽3c内的部分中产生固着效应。
诸如图12和图13中所示的凹槽3e也能够形成为防止热量传输至接合区6的外面的结构。凹槽3e从金属构件3与树脂构件4的接合表面朝向所述接合表面的相反侧的表面形成。换句话说，凹槽3e开设在金属构件3与树脂构件4的接合表面上，并且所述凹槽3e是封闭的，而且金属构件3的在金属构件3与树脂构件4的接合表面的相反侧上的表面处具有底部。
如狭缝3a相似，凹槽3e形成在接合区6的周边上的多个位置中，并且能够防止供给到金属构件3和树脂构件4的接合界面的热量在接合区6的平面方向上扩散到外面。在凹槽3e形成为禁止传输至接合区6的热量在平面方向上扩散到外面的构造的情况下，凹槽3e的底部形成在金属构件3的在其与树脂构件4的接合表面的相反侧上的表面上，并且凹槽3e不像前述的狭缝3a一样穿过金属构件3。因此，通过与狭缝3a形成在金属构件3中的情况下的刚性相比，金属构件3的刚性增大了。
在图9和图10中所示的凹槽3b形成在金属构件3中的构造中，在图3等中显示的加热体1可配置在与金属构件3和树脂构件4的接合表面侧相反的表面侧上，并且可在金属构件3侧加热金属构件3和树脂构件4的接合界面。此外，在图12和图13所示的凹槽3e形成在金属构件3中的构造中，可使用下文描述的高频加热装置11或激光辐照装置12从树脂构件4侧加热金属构件3和树脂构件4的接合界面。进一步，在图5至图7中所示的狭缝3a和图11中所示的凹槽3c和3d都形成在金属构件3中的构造中，可从金属构件3侧或者从树脂构件4侧执行加热。
进一步，如图14所示，当加热金属构件3与树脂构件4的接合界面时，可将高频加热装置11用作加热工具。当使用高频加热装置11加热接合界面时，将薄膜8插入金属构件3和树脂构件4之间，并且将高频加热装置11配置在树脂构件4的在接合表面5的相反侧的表面侧上。
当金属构件3为具有低导热系数和低电阻的诸如铝(Al)和铜(Cu)的非磁性材料时，可应用将薄膜8插入金属构件3和树脂构件4之间和使用高频加热装置11加热金属构件3和树脂构件4的接合界面的加热方法。
在这种情况下，具有比金属构件3的电阻高的电阻的磁性材料，例如，诸如铁(Fe)、镍(Ni)和钴(Co)的金属材料可用作薄膜8。通过使金属构件3与树脂构件4的接合表面经受例如用前述金属材料来电镀、喷涂或冷喷涂的各种加工方法提供薄膜8。通过使设置有薄膜8的金属构件3与树脂构件4堆叠、然后使用高频加热装置11高频加热插入在金属构件3与树脂构件4的接合界面中的薄膜8而使金属构件3和树脂构件4接合在一起。
通常，在金属构件3由具有高导热系数和低电阻的诸如铝(Al)和铜(Cu)的材料构成的情况下，当从金属构件3的其与树脂构件4的接合表面的相反侧的表面加热金属构件3并且使用传输到金属构件3的热量加热接合界面时，从接合表面的相反侧的表面传输到金属构件3的热量扩散至较大范围，输入到金属构件3和树脂构件4的接合区6的热量的效率较低，并且热量输入范围难于控制。
相反，当薄膜8插入金属构件3和树脂构件4的接合界面中并且使用配置在树脂构件4侧的高频加热装置11直接加热所述薄膜8时，将树脂构件4的接合表面5加热到在等于或高于树脂构件4的分解温度并且低于在树脂构件4中产生气泡的温度的范围内的温度。
在设置于金属构件3和树脂构件4的接合界面上的薄膜8被如此直接加热的情况下，即使在金属构件3由具有高导热系数和低电阻的材料构成时，也能够增大输入到接合区6中的热量的效率。进一步，通过由高频加热装置11构成加热体1并且使高频加热装置11的加热线圈形成与接合区6的尺寸对应的尺寸，能够控制输入到金属构件3和树脂构件4的接合界面的热量的范围。结果，能够通过在短期内利用简单工艺充分加热金属构件3和树脂构件4的接合界面来执行接合，并且能够获得足够的接合强度。在上述的构造中，仅将高频加热装置11用作加热金属构件3和树脂构件4的接合界面的加热工具，但是所述高频加热装置11可与加热体1和/或冷却体2一起使用。
进一步，如图15所示，在加热金属构件3和树脂构件4的接合界面的情况下，可将激光辐照装置12用作加热体1，并且通过利用来自激光辐照装置12的激光辐射辐照接合界面来执行加热。在通过利用来自激光辐照装置12的激光辐射辐照接合界面来执行加热的情况下，将薄膜9插入金属构件3和树脂构件4之间，并且将激光辐照装置12配置在与树脂构件4的接合表面5侧的相反侧的表面上。
当金属构件3为具有低导热系数和在红外区中的激光辐射的高反射率的诸如铝(Al)和铜(Cu)的材料时，能够应用将薄膜9插入金属构件3和树脂构件4之间、以及使用来自激光辐照装置12的激光辐射来加热金属构件3和树脂构件4的接合界面的加热方法。
在这种情况下，树脂构件4可由能够传递激光辐射的材料构成，并且例如铁(Fe)、镍(Ni)、钴(Co)和锌(Zn)的、具有比金属构件3在红外区中的激光辐射的反射率低的激光辐射的反射率的金属材料可用作薄膜9。通过使金属构件3与树脂构件4的接合表面经受例如用前述金属材料来电镀、喷涂或冷喷涂的各种加工方法提供薄膜9。
通过使设置有薄膜9的金属构件3与树脂构件4堆叠、然后通过使用来自激光辐照装置12的激光辐射辐照插入金属构件3与树脂构件4的接合界面中的薄膜9来加热所述接合界面，而使金属构件3和树脂构件4接合在一起。激光辐照装置12可由发射红外激光辐射的装置构成，诸如钇铝石榴石(YAG)激光器、半导体激光器或者二氧化碳激光器。
通常，在金属构件3由具有红外激光辐射的高反射率的诸如铝(Al)和铜(Cu)的材料构成的情况下，即使在使用激光辐射辐照金属构件3与树脂构件4的接合表面时，绝大多数辐射都在接合表面上被反射。结果，加热效率低，并且通过用具有激光辐射的辐照加热难于将金属构件3和树脂构件4接合在一起。
相反，将薄膜9插入金属构件3和树脂构件4的接合界面中，并且朝向薄膜9发射来自配置于树脂构件4侧上的激光辐照装置12的激光辐射的情况下，将树脂构件4的接合表面5加热到在等于或高于树脂构件4的分解温度并且低于在树脂构件4中产生气泡的温度的范围内的温度。
在如此通过激光辐射加热设置于金属构件3和树脂构件4的接合界面上的薄膜9的情况下，即使在金属构件3由具有激光辐射的高反射率的材料构成时，也能够增大输入到接合区6中的热量的效率，并且通过用激光辐射的辐照加热能够容易地实现金属构件3和树脂构件4的接合。进一步，通过由激光辐照装置12构成加热体1并且使来自激光辐照装置12的激光辐射的辐照范围形成与接合区6的尺寸对应的尺寸，能够控制输入到金属构件3和树脂构件4的接合界面的热量的范围。结果，能够通过在短期内利用简单工艺充分加热金属构件3和树脂构件4的接合界面来执行接合，并且能够获得足够的接合强度。在上述的本示例中，仅将激光辐照装置12用作加热金属构件3和树脂构件4的接合界面的加热工具，但是所述激光辐照装置12可与加热体1和/或冷却体2一起使用。

Claims (9)

1.一种通过加热使树脂和金属接合的接合方法，其包括：
通过将所述树脂和所述金属的接合界面加热到在等于或高于所述树脂的分解温度并且低于在所述树脂中产生气泡的温度的范围内的温度，使所述树脂和所述金属接合。
2.根据权利要求1所述的接合方法，其中：
从所述金属的在其与所述树脂的接合表面的相反侧的表面加热所述树脂和所述金属的所述接合界面；并且
将所述树脂的在其与所述金属的接合表面的相反侧的表面冷却到低于所述树脂的熔点的温度。
3.根据权利要求1或2所述的接合方法，其中，通过将薄膜插入所述树脂和所述金属的所述界面中并且从所述树脂的在其与所述金属的接合表面的相反侧的表面高频加热所述薄膜，执行所述树脂和所述金属的所述接合，所述薄膜具有比所述金属的电阻高的电阻。
4.根据权利要求1或2所述的接合方法，其中：
将具有比所述金属的激光反射率低的激光反射率的薄膜插入所述树脂和所述金属的所述界面中；
由能够传递激光辐射的金属构成所述树脂；并且
通过从所述树脂的在其与所述金属的接合表面的相反侧的表面朝向所述薄膜发射激光辐射并且加热所述薄膜，执行所述树脂和所述金属的所述接合。
5.根据权利要求1至4中任一项所述的接合方法，其中，加热后的所述树脂能够渗入的凹部形成在所述金属的在所述树脂和所述金属的接合区周围的区域内。
6.一种在通过加热使树脂和金属接合时使用的接合装置，其包括：
加热工具，其从所述金属的在其与所述树脂的接合表面的相反侧的表面加热所述树脂和所述金属的接合界面；以及
冷却工具，其将所述树脂的在其与所述金属的接合表面的相反侧的表面冷却到低于所述树脂的熔点的温度。
7.根据权利要求6所述的接合装置，其中，所述加热工具将所述树脂和所述金属的所述接合界面加热到在等于或高于所述树脂的分解温度并且低于在所述树脂中产生气泡的温度的范围内的温度。
8.根据权利要求6或7所述的接合装置，其中，凹部形成在所述金属的在所述树脂和所述金属的接合区周围的区域内。
9.根据权利要求6或7所述的接合装置，其中，穿透所述金属的狭缝形成在所述金属的在所述树脂和所述金属的接合区周围的区域内。
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CN109940899A (zh) * 2017-12-21 2019-06-28 通用汽车环球科技运作有限责任公司 用于金属-聚合物复合连接的激光诱导微锚结构和钝化层及其制造方法
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US20110139353A1 (en) 2011-06-16
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