CN103640212A - 过水组件激光焊接工艺 - Google Patents

过水组件激光焊接工艺 Download PDF

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CN103640212A
CN103640212A CN201310709557.8A CN201310709557A CN103640212A CN 103640212 A CN103640212 A CN 103640212A CN 201310709557 A CN201310709557 A CN 201310709557A CN 103640212 A CN103640212 A CN 103640212A
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water flowing
water
welding process
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CN103640212B (zh
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韩敏
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Runner Xiamen Corp
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Xiamen Runner Industrial 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
    • 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
    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/122—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
    • B29C66/1222—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a lapped joint-segment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/122—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
    • B29C66/1224—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a butt joint-segment
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/52—Joining tubular articles, bars or profiled elements
    • B29C66/522—Joining tubular articles
    • B29C66/5221—Joining tubular articles for forming coaxial connections, i.e. the tubular articles to be joined forming a zero angle relative to each other
    • 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
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/534—Joining single elements to open ends of tubular or hollow articles or to the ends of bars
    • B29C66/5344—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially annular, i.e. of finite length, e.g. joining flanges to tube ends
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—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
    • B29C66/733—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 optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence
    • B29C66/7332—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 optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being coloured
    • 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
    • B29C66/735—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
    • B29C66/7352—Thickness, e.g. very thin
    • B29C66/73521—Thickness, e.g. very thin of different thickness, i.e. the thickness of one of the parts to be joined being different from the thickness of the other part
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L47/00—Connecting arrangements or other fittings specially adapted to be made of plastics or to be used with pipes made of plastics
    • F16L47/02—Welded joints; Adhesive 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
    • 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
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • 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
    • B29C66/919—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
    • 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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Abstract

本发明提供一种过水组件激光焊接工艺，包括一过水软管以及套于过水软管端部的软管接头，所述软管接头与过水软管的内表面设有深色吸光部，所述软管接头外周为激光透射部，所述软管接头与过水软管连接处在激光束条件下进行激光熔接。本发明通过利用激光焊接的方法，实现了PERT等塑料过水组件与其他过水料件的连接，该方法解决了目前塑料过水组件，尤其PERT过水组件与出水组件联接时采用旋转焊工艺、一体成型工艺、热板焊工艺等方法易出现焊接强度差，变形量大，密封性无法保障等问题，从而降低了生产成本，提高了生产质量。

Description

过水组件激光焊接工艺
技术领域
本发明涉及一种过水组件激光焊接工艺，主要应用于浴室花洒和莲蓬头；厨房/浴室龙头；厨房喷枪等过水组件的生产工艺中。
背景技术
随着人民生活水平日益提高，对生活环境质量要求也越来越高，在家庭厨房、卫生间所用龙头及其他配件过水组件大多采用铜材质，铜材质中含有一定比例铅、砷等对人体有害的化学成分，造成消费者身体隐患疾病，为克服此产品材质缺陷，市面上有很多卫浴公司都在对铜材质过水组件的龙头机其他产品进行技术创新，采用更佳的材料取代铜材质，目前运用较多的是用塑料如：PE、PEX等，由于这些塑料耐热温度在60℃左右，无法在高温热水的环境下长期使用，因此，现有的过水设备采用了PERT材料。PERT是一种可用于热水的非交联的聚乙烯管，也是中密度聚乙烯管，其不仅具有耐高温的特点，还具有柔韧性好，耐压性好，无毒，无味，无污染、耐低温等特点，十分适合过水组件的材料。且过水组件由铜材质更改为PERT等塑料材质，材料成本和零件加工成本大幅度降低，减少了铜材质过水组件所含重金属对人体的伤害，从而提升产品的市场竞争力。
在其它产品塑料出水组件联接时，现有的技术主要采用旋转焊工艺、一体成型工艺、热板焊工艺等连接工艺方法，这些方法应用于PERT材料时主要存在以下问题：
旋转焊：
①  PERT材质偏软，在旋转焊接时极易变形，导致未完全摩擦、形成虚焊，制程10％以上漏水；
②        对于双方定位焊接，受材质太软影响，焊后存在25%以上位置偏差，导致整组产品无法准确组装定位，报废率极高；
③        焊接强度不稳定；
④        焊接长度不易控制。
热板焊：
①        PERT材料熔点低，焊接变形量大，焊后溢料堵孔，影响流量；
②        受预热变形影响，焊接尺寸及密封性无法保障。
一体成型工艺：
①        加工成本高，工艺复杂；
为此，需要设计一种焊接强度稳定，易于控制，保证连接密封性的过水组件焊接方法。
发明内容
本发明对上述问题进行了改进，即本发明要解决的技术问题是设计一种保证连接密封性的过水组件焊接方法。
本发明的具体实施方案是：一种过水组件激光焊接工艺，包括一过水软管以及套于过水软管端部的软管接头，所述软管接头与过水软管的内表面设有深色吸光部，所述软管接头外周为激光透射部，所述软管接头与过水软管连接处在激光束条件下进行激光熔接。
优选的，所述激光透射部材料透光率≥50%。
优选的，所述过水接头内表面深色吸光部颜色为黑色或易吸光的深色。
优选的，所述过水接头激光透射部厚度在1.5～3.5mm。
优选的，所述过水软管与软管接头配合长度≥5mm。
优选的，所述过水软管与软管接头为过盈配合，单边过盈量0.03～0.08mm。
优选的，所述过水组件激光焊接时，组件旋转速度≤40mm/s。
与现有技术相比，本发明具有以下有益效果：该方法解决了目前塑料过水组件，尤其PERT过水组件与出水组件联接时采用旋转焊工艺、一体成型工艺、热板焊工艺等方法易出现焊接强度差，变形量大，密封性无法保障等问题，从而降低了生产成本，提高了生产质量。本发明在出水软管与软管接头处具有一定的预压力，大大加强了激光熔接过程中相互的热接触。
附图说明
图1为本发明焊接结构示意图。
     图中：10-过水软管，20-软管接头，110-过水通道，210-深色吸光部，220-激光透射部。
具体实施方式
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。
如图1所示，一种过水组件激光焊接工艺，包括一过水软管10以及套于过水软管10端部的软管接头20，过水软管10及软管接头20具有相连通的110-过水通道，所述软管接头20与过水软管10的内表面设有深色吸光部210，所述软管接头20外周为激光透射部220，所述软管接头20与过水软管10连接处在激光束条件下进行激光熔接。所述激光透射部220材料透光率≥50%，过水接头内表面深色吸光部210颜色为黑色或易吸光的深色。
过水接头激光透射部220厚度在1.5～3.5mm为宜，过厚则需要较高激光调整激光发射功率，厚度过薄则易出现外形受热变形而影响连接强度，过水软管与软管接头配合长度至少大于5mm，以保证连接处具有较强的抗压强度。
过水软管与软管接头为过盈配合，单边过盈量0.03～0.08mm，以使出水软管与软管接头处具有一定的预压力，大大加强了激光熔接过程中相互的热接触。
焊接时，过水组件夹于夹具上，激光发射器发射激光垂直于夹具设置，使激光对准焊接部，开启夹具，使过水组件旋转的同时进行激光焊接，旋转时，组件旋转速度应≤40mm/s，优选地，在20 mm/s～40mm/s的范围内，可实现在最低的功率上达到最佳的焊接效果。
激光焊接工艺参数设置对比表：
序号 透光层厚度 激光发射器功率 夹具座旋转速度
1 ∮1.5--∮2.0mm 5A---10A 35--40mm/s
2 ∮2.0--∮3.0mm 10A---20A 30--35mm/s
3 ∮3.0--∮3.5mm 20A---25A 25--30mm/s
以上所述仅为本发明的较佳实施例，凡依本发明申请专利范围所做的均等变化与修饰，皆应属本发明的涵盖范围。

Claims (8)

1.一种过水组件激光焊接工艺，其特征在于：包括一过水软管以及套于过水软管端部的软管接头，所述软管接头与过水软管的内表面设有深色吸光部，所述软管接头外周为激光透射部，所述软管接头与过水软管连接处在激光束条件下进行激光熔接。
2.根据权利要求1所述的一种过水组件激光焊接工艺，所述过水软管与软管接头材料为PERT。
3.根据权利要求1所述的一种过水组件激光焊接工艺，所述激光透射部材料透光率≥50%。
4.根据权利要求1所述的一种过水组件激光焊接工艺，所述过水接头内表面深色吸光部颜色为黑色或易吸光的深色。
5.根据权利要求1所述的一种过水组件激光焊接工艺，所述过水接头激光透射部厚度在1.5～3.5mm。
6.根据权利要求1所述的一种过水组件激光焊接工艺，所述过水软管与软管接头配合长度≥5mm。
7.根据权利要求1所述的一种过水组件激光焊接工艺，所述过水软管与软管接头为过盈配合，单边过盈量0.03～0.08mm。
8.根据权利要求1所述的一种过水组件激光焊接工艺，所述过水组件激光焊接时，组件旋转速度≤40mm/s。
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