CN102950766B - 一种热塑性塑料的激光透射焊接方法 - Google Patents

一种热塑性塑料的激光透射焊接方法 Download PDF

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CN102950766B
CN102950766B CN201210454722.5A CN201210454722A CN102950766B CN 102950766 B CN102950766 B CN 102950766B CN 201210454722 A CN201210454722 A CN 201210454722A CN 102950766 B CN102950766 B CN 102950766B
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rigid plastics
laser beam
welded framework
welded
laser
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CN102950766A (zh
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曹宇
李峰平
赵宗礼
王陇花
李剑阳
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Wenzhou University
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
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    • B29C65/1654—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C65/16—Laser beams
    • B29C65/1677—Laser beams making use of an absorber or impact modifier
    • B29C65/168—Laser beams making use of an absorber or impact modifier placed at the interface
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
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    • B29C66/05—Particular design of joint configurations
    • B29C66/303—Particular design of joint configurations the joint involving an anchoring effect
    • B29C66/3034—Particular design of joint configurations the joint involving an anchoring effect making use of additional elements, e.g. meshes
    • B29C66/30341—Particular design of joint configurations the joint involving an anchoring effect making use of additional elements, e.g. meshes non-integral with the parts to be joined, e.g. making use of extra elements
    • 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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    • B29C66/349—Cooling the welding zone on the welding spot
    • B29C66/3494—Cooling the welding zone on the welding spot while keeping the welding zone under pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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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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    • B29C65/16—Laser beams
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    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/735—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 extensive physical properties of the parts to be joined
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Abstract

本发明提供了一种热塑性塑料的激光透射焊接方法，包含：(1)在上、下硬质塑料之间摆放焊接骨架；(2)使上硬质塑料、焊接骨架和下硬质塑料接触压紧；(3)将上、下硬质塑料和焊接骨架放置在冷却液体内；(4)使用激光束从上硬质塑料的一侧射入，聚焦在焊接骨架上，形成焊接点；(5)使上、下硬质塑料与焊接点接触的部分熔化；(6)熔化的塑料通过焊接骨架上与焊接点临近的通孔相互贯通融合；(7)停止照射或移开激光束；(8)重复步骤(4)-(7)。该激光透射焊接方法可实现精确焊接路径和焊接强度控制，增加焊接件的整体强度和刚度，任意改变焊接接头局部部位的材料原有性能，防止发生灼烧缺陷，并可重复实现焊接与分离。

Description

一种热塑性塑料的激光透射焊接方法
技术领域
本发明属于激光焊接领域，具体涉及一种热塑性塑料的激光透射焊接方法。
背景技术
热塑性塑料是一类应用最广的塑料，它是以热塑性树脂为主要成分，并添加各种助剂而配制成的一类塑料。在一定的温度条件下，塑料能软化或熔融成任意形状，冷却后形状不变；这种状态可多次反复而始终具有可塑性，且这种反复只是一种物理变化，称这种塑料为热塑性塑料。聚乙烯、聚丙烯、聚氯乙烯、聚苯乙烯、聚甲醛，聚碳酸酯，聚酰胺、丙烯酸类塑料、其它聚烯烃及其共聚物、聚砜、聚苯醚，氯化聚醚等都是热塑性塑料。热塑性塑料中树脂分子链都是线型或带支链的结构，分子链之间无化学键产生，加热时软化流动，冷却变硬。
塑料及其复合材料的连接方法通常有三种：机械连接、黏合剂黏结和焊接。(1)机械连接包括使用如金属或塑料螺钉的单独紧固件，进行铆合或压合接头连接。(2)黏合剂黏结是将黏合剂涂于将要连接的部件之间，起到连接各部件的作用。(3)焊接是通过加热将界面处的聚合物熔融或软化，在一定的压力和时间作用下，从而使聚合物分子链通过界面进行扩散形成链缠结，最终获得焊接点强度。焊接方法又根据所采用的加热方式分为两大类：外加热和内加热。外加热法通过对流或传导来加热焊接表面，包括热工具焊、热气焊、挤出焊、内植感应焊和内植阻抗焊。内加热法是通过技术直接在材料内部产生热源，从而取代外部加热。它分为两类：机械加热和电磁加热。机械内加热法是通过表面摩擦或分子间摩擦将机械能转化为热，包括超声波，振动和旋转焊接。电磁内加热法依赖于吸收电磁辐射从而转化为热，包括红外线，激光，射频和微波焊接。
传统的热塑性塑料的连接方法有许多弊病，采用螺钉、卡环等机械连接强度不易达到要求且不能对连接表面质量有所要求；黏结剂黏结方法，需经过表面打毛、涂胶、粘接、固化、电烙铁烫平、修整等工序，全部采用手工操作，劳动强度大，工序多，生产效率低，质量难以保证，而且黏结剂的挥发成分污染环境，影响操作人员的身体健康；采用外部加热焊接，塑料件容易和加热源粘结在一起，且会造成空气污染；内植焊接的植入物要留在焊接面上，会影响焊接接头强度；机械内加热法会使最终产品有振动应力和热应力的残余，加速制品的老化。而激光焊接能生成精密、牢固和密封(不透气和不漏水)的焊缝，而且树脂降解少，产生的碎屑少，由于激光的非接触特性，不会产生污染。另一个优点是激光焊接比采用其他连接方式所产生的振动应力和热应力小，意味着制品或者装置的内部组织的老化速度更慢，因此更适合应用于易损坏的制品如电子传感器或微电机系统的制造。
激光透射焊接是近几年发展起来的一种新型塑料焊接工艺，其原理是红外激光束(波长一般在800-1060nm)通过反射镜、透镜或光纤组成的光路系统，将激光器所产生的能量聚焦在待焊接区域。两个待焊接件必须有一个对激光束是透明的，即激光光束穿透它却没有能量的损失，另外一个是不透明的，即吸收激光辐射的能量；为了增加材料吸收辐射能的能力，两个待焊接件的接触面上设置有吸收激光的添加剂涂层。辐射穿透两个待焊接部件中的透明的焊接件，另外不透明的那个部件在接触面上吸收激光辐射形成热作用区，在热影响区中的塑料被融化；在随后的凝固过程中，已融化的材料形成接头，待焊接的部件即被连接起来。但是，目前的激光透射焊接技术仅能起到连接的作用，不能使焊接后的热塑性塑料材料性能如导电性、导热性等发生改变；由于塑料的低熔点、易灼烧特点，激光焊接工艺参数范围很难优化；并且焊接后的两个工件基本都不可再分离。
发明内容
本发明针对上述现有技术的不足，提供了一种热塑性塑料的激光透射焊接方法；该热塑性塑料的激光透射焊接方法可实现精确焊接路径和焊接强度控制，增加焊接件的整体强度和刚度，任意改变焊接接头局部部位的材料原有性能，防止发生灼烧缺陷，并可重复实现焊接与分离。
本发明是通过如下技术方案实现的：
一种热塑性塑料的激光透射焊接方法，包含以下步骤：
(1)在两个待焊接的上、下硬质塑料之间摆放一焊接骨架；所述上硬质塑料为可透射激光束的热塑性塑料；所述焊接骨架为可吸收激光束的硬质材料，所述焊接骨架的熔点高于上硬质塑料和下硬质塑料的熔点，在焊接骨架上设置有若干个通孔；
(2)施加压力使上硬质塑料、焊接骨架和下硬质塑料接触压紧；
(3)将接触压紧的上、下硬质塑料和焊接骨架放置在冷却液体内浸泡，所述冷却液体要求可透射激光束并且不与上、下硬质塑料发生化学反应；
(4)使用激光束从上硬质塑料的一侧射入，聚焦在焊接骨架上，形成焊接点；
(5)调节激光束的功率使焊接点的温度高于上硬质塑料和下硬质塑料的熔点，并低于焊接骨架的熔点，从而使上、下硬质塑料与焊接点接触的部分熔化；
(6)熔化的塑料在压力作用下通过焊接骨架上与焊接点临近的通孔相互贯通融合；
(7)停止照射或移开激光束，失去聚焦激光束照射的焊接骨架焊接点及附近区域迅速降温，实现焊接点位置上、下硬质塑料的牢固连接；
(8)重复步骤(4)-(7)，使激光束连续移动扫描可实现连续轨迹焊接，或者使激光束断续扫描定点照射或关闭可实现点位焊接。
与传统的激光透射焊接方法相比，本发明所述热塑性塑料的激光透射焊接方法有如下有益效果：
1、本发明通过在上、下硬质塑料之间增设焊接骨架，使焊接骨架在焊接后与上、下硬质塑料成为一体结构，大大增强了焊接后热塑性塑料的强度。
2、本发明中由于焊接骨架的存在，当再次使用激光束照射焊接后的热塑性塑料中的焊接骨架，并对上、下硬质塑料施加拉力，上、下硬质塑料与焊接骨架的已焊位置被聚焦激光束照射迅速升温，当温度超过上、下硬质塑料的熔点后，接触的部分发生熔化，在拉力作用下，可以实现已焊点的分离。因此，通过施加压力或拉力，采用同样的激光扫描运动，即可重复实现上、下硬质塑料件的焊接或分离。
3、本发明中增设了焊接骨架，而焊接骨架的材质可以为金属片、陶瓷片或者硅片等，也可以是由多种材料堆叠组成的夹层结构或拼接组成的拼图结构；因而，通过设计不同材料、不同尺寸形状的焊接骨架，可使得焊接后的热塑性塑料焊接接头的质量分布、导电性、导热性和绝缘性等材料性能发生局部改变，获得任意的质量分布特征以及良好的导电/绝缘、导热/隔热特性。
4、本发明中通过在焊接骨架上设置若干个通孔，使得熔融塑料可以穿过通孔渗透到另一侧，从而使上、下硬质塑料的结合更加紧密。通孔的位置、大小、形状可以任意设置，满足不同位置具有不同焊接接头强度的特定需要，这对于非均匀分布载荷场合十分适用。
5、本发明通过在冷却液体中实施焊接，通过对激光束的局部加热作用和良好的液体冷却作用进行热平衡操纵，使得更易于通过调节激光束功率控制焊接点的温度，可有效防止塑料灼烧，加快焊缝冷却速度；同时减少焊缝的热影响区，使焊点细小，焊接精度更高。冷却液体包围的焊接环境，可以防止焊缝氧化，使焊接接头强度更高、成形更美观。
与传统的电磁感应焊接方法相比，本发明所述热塑性塑料的激光透射焊接方法有如下有益效果：
1、本发明无需导磁片，而采用了可用材料广泛的焊接骨架，其材料可以是金属或非金属，只要求焊接骨架基体能有效吸收激光或者表面刷涂吸收激光涂料以及导热性良好(激光直接作用深度很浅，几十纳米至几微米，需靠导热快速加热与之接触的上下硬质塑料)，因此，本焊接方法的适用性更加广泛。
2、焊接骨架的材质可以为金属片、陶瓷片或者硅片等，也可以是由多种材料堆叠组成的夹层结构或拼接组成的拼图结构；因而，通过设计不同材料、不同尺寸形状的焊接骨架，可使得焊接后的热塑性塑料焊接接头的质量分布、导电性、导热性和绝缘性等材料性能发生局部改变，获得任意的质量分布特征以及良好的导电/绝缘、导热/隔热特性。
3、电磁感应焊接是整个导磁片的接触面都被焊接，不能控制精确的焊接路径，不易实现精细焊接。本发明所述的焊接方法中只有激光扫描过的地方才会被焊接，从而可使焊接路径可选，焊接位置更精确，较容易实现精细焊接；通孔的位置、大小、形状可以任意设置，满足不同位置不同的焊接接头强度需要，这对于非均匀分布载荷场合十分适用。
附图说明
图1为本发明所述热塑性塑料的激光透射焊接方法实施情况示意图；
图中各标号的含义如下：
上硬质塑料-1，下硬质塑料-2，焊接骨架-3，通孔-4，夹持机构-5，冷却液体-6，激光束-7，激光器-8。
具体实施方式
本发明所述的上硬质塑料为可透射激光束的热塑性塑料，本发明不对其具体类型进行限制，只要该塑料具有热塑性并且能够透射激光束即可。这种塑料包括尼龙6(PA6)或尼龙66(PA66)的聚酰胺(PA)、聚乙烯(PE)、聚丙烯(PP)、聚对苯二甲酸乙二醇酯(PET)、聚苯乙烯、ABS、聚甲基丙烯酸甲酯(PMMA)、聚碳酸酯(PC)和聚对苯二甲酸丁二醇酯(PBT)等。“透射激光束”是指激光束的透射率要大于80％。
本发明不对下硬质塑料做要求，其可以透射激光束，也可以吸收激光束，只要其可与上硬质塑料熔接即可。
本发明所述的激光束包括由Nd:YAG激光器、红宝石激光器、氦氖激光器、光纤激光器、准分子激光器或半导体激光器产生的激光束。
下面结合附图和具体实施方式对本发明做进一步详细的说明。
实施例一：
如图1所示，本发明提供了一种热塑性塑料的激光透射焊接方法，包含以下步骤：
(1)在两个待焊接的上硬质塑料1和下硬质塑料2之间摆放一焊接骨架3；所述上硬质塑料1为可透射激光束的热塑性塑料，所述焊接骨架3为可吸收激光束的硬质材料，本实施例中上硬质塑料1和下硬质塑料2采用聚对苯二甲酸乙二醇酯(PET)，厚度为10mm，下硬质塑料2采用聚碳酸酯(PC)，厚度10mm；焊接骨架3采用厚度为1mm的薄铜片；所述焊接骨架3的熔点高于上硬质塑料1和下硬质塑料2的熔点，在焊接骨架3上设置有若干个通孔4；通孔4的位置、大小、形状可以根据实际需要任意设置。
(2)采用夹紧机构5夹紧上硬质塑料1和下硬质塑料2，即施加压力使上硬质塑料1、焊接骨架3和下硬质塑料2接触压紧；
(3)将接触压紧的上硬质塑料1、焊接骨架3和下硬质塑料2放置在冷却液体6内浸泡；本实施例中的冷却液体6为水。
(4)采用波长为1064纳米的Nd:YAG激光器8，激光功率为10W，输出激光束7，使激光束7从上硬质塑料1的一侧射入，聚焦在焊接骨架3上，形成焊接点A；
(5)调节激光束7的功率使焊接点A的温度高于上硬质塑料1和下硬质塑料2的熔点，并低于焊接骨架3的熔点；上、下硬质塑料1、2与焊接点A接触的部分熔化；
(6)熔化的塑料在压力作用下通过焊接骨架3上与焊接点A临近的通孔4相互贯通融合；
(7)停止照射或移开激光束7，失去聚焦激光束照射的焊接骨架3上的焊接点及附近区域迅速降温，实现焊接点位置上、下硬质塑料的牢固连接；
(8)重复步骤(4)-(7)，使激光束7连续移动扫描可实现连续轨迹焊接。
实施例二：
本发明提供了一种热塑性塑料的激光透射焊接方法，包含以下步骤：
(1)在两个待焊接的上硬质塑料1和下硬质塑料2之间摆放一焊接骨架3；所述上硬质塑料1为可透射激光束的热塑性塑料；所述焊接骨架3为可吸收激光束的硬质材料，所述焊接骨架3的熔点高于上硬质塑料1和下硬质塑料2的熔点，在焊接骨架3上设置有若干个通孔4；本实施例中上硬质塑料1采用聚碳酸酯(PC)，厚度为50mm；下硬质塑料2采用聚对苯二甲酸丁二醇酯(PBT)，厚度100mm，焊接骨架3采用厚度为0.5mm的氧化铝陶瓷片；
(2)采用夹紧机构5夹紧上硬质塑料1和下硬质塑料2，即施加压力使上硬质塑料1、焊接骨架3和下硬质塑料2接触压紧；
(3)将接触压紧的上硬质塑料1、焊接骨架3和下硬质塑料2放置在冷却液体6内浸泡；本实施例中的冷却液体6为乙醇。
(4)采用波长为500-1000nm的半导体激光器8，功率为900W，输出激光束7，使用激光束7从上硬质塑料1的一侧射入，聚焦在焊接骨架3上，形成焊接点A；
(5)调节激光束7的功率使焊接点A的温度高于上硬质塑料1和下硬质塑料2的熔点，并低于焊接骨架3的熔点；上、下硬质塑料1、2与焊接点A接触的部分熔化；
(6)熔化的塑料在压力作用下通过焊接骨架3上与焊接点A临近的通孔4相互贯通融合；
(7)停止照射或移开激光束，失去聚焦激光束照射的焊接骨架焊接点及附近区域迅速降温，实现焊接点位置上、下硬质塑料的牢固连接；
(8)重复步骤(4)-(7)，使激光束断续扫描定点照射或关闭可实现点位焊接。

Claims (3)

1.一种热塑性塑料的激光透射焊接方法，其特征在于，包含以下步骤：
(1)在两个待焊接的上、下硬质塑料之间摆放一焊接骨架；所述上硬质塑料为可透射激光束的热塑性塑料；所述焊接骨架为可吸收激光束的硬质材料，所述焊接骨架的熔点高于上硬质塑料和下硬质塑料的熔点，在焊接骨架上设置有若干个通孔；
(2)施加压力使上硬质塑料、焊接骨架和下硬质塑料接触压紧；
(3)将接触压紧的上、下硬质塑料和焊接骨架放置在冷却液体内浸泡；所述冷却液体要求可透射激光束并且不与上硬质塑料和下硬质塑料发生化学反应；
(4)使用激光束从上硬质塑料的一侧射入，聚焦在焊接骨架上，形成焊接点；
(5)调节激光束的功率使焊接点的温度高于上硬质塑料和下硬质塑料的熔点，并低于焊接骨架的熔点；上、下硬质塑料与焊接点接触的部分熔化；
(6)熔化的塑料在压力作用下通过焊接骨架上与焊接点临近的通孔相互贯通融合；
(7)停止照射或移开激光束，失去聚焦激光束照射的焊接骨架焊接点及附近区域迅速降温，实现焊接点位置上、下硬质塑料的牢固连接；
(8)重复步骤(4)-(7)，使激光束连续移动扫描可实现连续轨迹焊接，或者使激光束断续扫描定点照射或关闭可实现点位焊接。
2.根据权利要求1所述的热塑性塑料的激光透射焊接方法，其特征在于，所述焊接骨架为金属片、陶瓷片或者硅片。
3.根据权利要求1所述的热塑性塑料的激光透射焊接方法，其特征在于，所述冷却液体为水溶液。
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