CN103796816B - 用于将热塑性聚合物粘合至热固性聚合物部件的方法 - Google Patents

用于将热塑性聚合物粘合至热固性聚合物部件的方法 Download PDF

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CN103796816B
CN103796816B CN201280036708.1A CN201280036708A CN103796816B CN 103796816 B CN103796816 B CN 103796816B CN 201280036708 A CN201280036708 A CN 201280036708A CN 103796816 B CN103796816 B CN 103796816B
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polymer
thermoplastic polymer
implant
thermosetting
thermoplastic
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CN103796816A (zh
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M·J·L·范托勒
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GKN Fokker Aerospace BV
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Fokker Aerostructures BV
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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
    • 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
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • 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
    • B29C65/34—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"
    • 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
    • B29C65/34—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"
    • B29C65/3468—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" characterised by the means for supplying heat to said heated elements which remain in the join, e.g. special electrical connectors of windings
    • 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
    • B29C65/34—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"
    • B29C65/3472—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" characterised by the composition of the heated elements which remain in the joint
    • B29C65/3484—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" characterised by the composition of the heated elements which remain in the joint being non-metallic
    • B29C65/3488—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" characterised by the composition of the heated elements which remain in the joint being non-metallic being an electrically conductive polymer
    • 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
    • B29C65/76—Making non-permanent or releasable joints
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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
    • B29C66/003—Protecting areas of the parts to be joined from overheating
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/034—Thermal after-treatments
    • B29C66/0342—Cooling, e.g. transporting through welding and cooling zone
    • 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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    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
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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
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/348—Avoiding melting or weakening of the zone directly next to the joint area, e.g. by cooling
    • 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
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
    • B29C66/474—Joining single elements to sheets, plates or other substantially flat surfaces said single elements 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
    • B29C66/70—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
    • B29C66/72—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 structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
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    • B29C66/72141—Fibres of continuous length
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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
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    • B29C66/723—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 structure of the material of the parts to be joined being multi-layered
    • 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
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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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    • B29C66/73—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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    • 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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    • 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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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • High Energy & Nuclear Physics (AREA)
  • Plasma & Fusion (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Adhesives Or Adhesive Processes (AREA)
  • Laminated Bodies (AREA)

Abstract

本发明涉及一种将热塑性聚合物粘合到热固性聚合物部件上的方法，所述热塑性聚合物具有高于所述热固性聚合物固化温度的熔化温度。该方法包含下列步骤：提供固化的热固性聚合物部件，往部件在要粘合的所述热固性聚合物部件的至少一部分处包含热塑性聚合物植入物，在与所述部件接触的至少待粘合的部分处定位热塑性聚合物，将上述组件进行加热到所述热塑性聚合物的熔化温度，由此植入物热塑性聚合物熔化并与所述热塑性聚合物融合；以及冷却所述组件。所述热塑性聚合物具有超过所述热固性聚合物固化温度的熔化温度，且所述植入物设计成在粘合步骤期间，避免在植入物和热固性聚合物界面处超过所述热固性聚合物的最大操作温度下加热。

Description

用于将热塑性聚合物粘合至热固性聚合物部件的方法
技术领域
本发明涉及一种用于将热塑性聚合物粘合至热固性聚合物部件的方法。本发明还涉及一种用于将热固性聚合物部件粘合至另一个热固性聚合物部件的方法。本发明还涉及一种至少在待粘合的热固性聚合物部件的一部分处包含热塑性聚合物的植入物的固化的热固性聚合物部件，以及具有形成粘合性表面的热塑性聚合物的植入物的未固化或部分固化的热固性聚合物部件。本发明还涉及一种具有热塑性表面的固化的热固性聚合物部件与焊接到其上的热塑性聚合物部件的组合件。
背景技术
包括低聚物的热塑性(纤维增强)聚合物越来越多地用作建筑材料，因为其具有循环利用的可能性。热塑性聚合物可被加热以使其软化(非晶形热塑塑料)或者最终将其熔化(半结晶热塑塑料)，并随后冷却以使其回到其固体状态。这种温度诱致的物理变化一般是可逆的，这使得热塑性聚合物可循环利用。在固体非晶形热塑塑料中，聚合物分子链以随机方式排布，而在固体半结晶热塑塑料中，其某些部分即结晶区包含以有序方式排布的聚合物分子链。即便使用措辞‘熔融’或‘熔化’，本发明仍不局限于一种类型的热塑性聚合物。热塑性聚合物具有玻璃化转变温度(Tg)，在高于该玻璃化转变温度下进一步加热，发生渐进软化。在显著高于玻璃化转变温度的温度下，非晶形热塑塑料表现为如同高粘度流体，而半结晶聚合物在该温度区域中仍为固体。半结晶热塑塑料具有熔融温度(Tm)，在高于熔融温度下，该材料熔化并且表现为如同流体。随着温度进一步增加，粘度迅速下降。
热固性聚合物通常为交联聚合物，其包含树脂，例如环氧化物(常称为环氧树脂)，双马来酰亚胺，不饱和聚酯和乙烯酯聚合物。在固化前，热固性聚合物通常包含树脂(单体)和硬化剂，它们一起反应以产生交联聚合物。可将固化设计为在室温下或在通常范围在80到200℃之间的更高温度下发生。在固化期间，该单体和硬化剂反应并且该混合物的粘度增加，直至其变成交联固态聚合物为止，所述状态通过温度改变不可逆，除非热固性聚合物在高于其降解温度的温度下降解。固化之后，热固性聚合物还具有玻璃化转变温度，在该玻璃化转变温度以上，热固性聚合物发生相当大程度的软化并且热固性聚合物表现为如同橡胶。
聚合物复合材料包含嵌入基体聚合物中的纤维或颗粒增强物，其可为热固性或热塑性的。熟知的聚合物复合物包含玻璃纤维增强的聚酯树脂和碳纤维增强的环氧树脂。这些复合物均将热固性聚合物用作基体，并因此经常称之为热固性复合物。
热固性(复合)聚合物的一个主要缺点在于，它们一般不可焊接，因为热固性聚合物不可通过升高和降低温度来熔化和再凝固。热固性(复合)聚合物通常通过粘合剂粘合或螺栓连接被粘附至其它部件，所述两种方式均有缺点。粘合剂粘合成本高，有时对环境有危害，并且所达到的粘合质量一般对工艺参数变化很敏感。另一方面，螺栓连接在待粘合部件中产生孔，这可能导致应力集中和过早被损坏。
WO2007/109855A1公开了一种用于将热塑性模制件粘附到热固性聚合物的模制件的方法，其设置有热塑性聚合物的嵌件。该粘附是通过使热塑性模制件与待粘合件接触并且将该整体加热至热塑性模制件的熔化温度来进行，其中嵌件的热塑性聚合物熔化并且与热塑性模制件融合。该加热是通过高频焊接进行。
Pratt等人的文章∶“Method of ultrasonically welding RIM parts usingthermoplastic inserts”，Motorola Technical Developments，第27卷，1996年5月1日，第200页至第201页也描述了一种用于通过在Rim尼龙部分中提供热塑性嵌件并且施加超声波焊接而将热塑性模制件粘附至热固性RIM尼龙聚合物的模制件的方法。
US2002/0113066A1还公开了另一种用于将热塑性模制件粘附至热固性聚合物的模制件的方法。热固性模制件通过将其与其中已经加入铁磁粒子的热塑性材料层共固化，获得。以此方式，生成粘合性表面来藉由超声波焊接粘合该热塑性模制件。
PCT/AU2007/001296描述了一种用于将热塑性连接器粘合至例如热固性复合管的方法，该复合管设置有热塑性嵌件。通过加热和再冷却该热塑塑料来实现粘合。
理想的是，向较宽范围的热固性聚合物或热固性聚合物复合物提供这样的可能性，即通过焊接将它们粘合至另一个热固性聚合物或热固性聚合物复合物或热塑性聚合物(复合物)的可能性。
本发明提供一种用于通过向热固性聚合物(复合物)提供具有可热粘合表面的热塑性植入物而将热固性聚合物(复合物)部件粘合至另一个热固性聚合物部件的方法。
本发明还提供一种至少在待粘合的热固性聚合物部件的一部分处包热塑性聚合物的植入物的固化的热固性聚合物部件，以及具有形成粘合性表面的热塑性聚合物的植入物的未固化或部分固化的热固性聚合物部件。
本发明还提供一种具有热塑性表面的固化的热固性聚合物部件与热塑性聚合物的组合件。
本发明还提供一种具有形成可热粘合表面的热塑性聚合物(部件)的植入物的未固化或部分固化的热固性聚合物部件，以及一种具有热塑性表面的固化的热固性聚合物部件与焊接到其上的热塑性聚合物部件的组合件。
发明内容
在第一方面，本发明提供一种用于将热塑性聚合物(部件)粘合至热固性聚合物部件的方法，该热塑性聚合物具有超过热固性聚合物的固化温度的熔融温度，该方法包含以下步骤：a)提供热塑性聚合物，b)提供未固化或部分固化的热固性聚合物部件，其具有低于热塑性聚合物的熔融温度的固化温度并且至少在待粘合的热固性聚合物部件的一部分处包含热塑性聚合物的植入物，c)使热塑性聚合物与至少待粘合的所述部分接触定位，d)将热塑性聚合物和热固性聚合物部件加热至热塑性聚合物的熔融温度，因此植入物的热塑性聚合物熔化并且与热塑性聚合物融合，并由此该未固化的热固性聚合物部件和植入物的热塑性聚合物至少部分互相渗透；和e)冷却热塑性聚合物和固化的热固性聚合物部件的组合件，使得所述热塑性聚合物粘合至所述固化的热固性聚合物部件，其中热塑性聚合物具有超过热固性聚合物的固化温度的熔融温度，并且将植入物设计成使得在粘合步骤d)期间，在植入物与热固性聚合物部件的界面处，避免在高于热固性聚合物的最大操作温度下加热。
聚合物(复合物)的最大操作温度为本领域的技术人员所熟知，并且通常由供应商提供。
在根据本发明的方法中，热塑性聚合物的植入物充当热固性聚合物(复合物)部件的散热片，因此为熔化待粘合的热塑性聚合物以及植入物的热塑性聚合物所施加的热量大体上位于待焊接的界面处，而通过熔化植入物的热塑性聚合物，吸收这一热量。根据本发明，在热粘合期间通过焊接来保持在热塑性植入物中的温度梯度，使得即便在高于这种降解温度下加热时，在植入物与热固性聚合物(复合物)部件的界面处的温度足够低以不致显著降解热固性聚合物。这避免在热固性聚合物(复合物)和植入物之间的界面处过度加热，并且因此给予通过焊接将热塑性聚合物粘合至热固性聚合物部件的可能性，所述热塑性聚合物具有超过热固性聚合物的固化温度的熔融温度。
上述优点对于航天和航空器应用特别有用，其中使用的相对高的温度要求使用具有相对高熔融温度的热塑性聚合物。
在本发明的实施例中，提供一种方法，其中以J/°K/m计的每单位长度植入物的热容量大于在步骤d)期间施加到每单位长度组合件的热量。换句话说，植入物的定位和截面尺寸，以及植入物的热塑性聚合物的选择，使得满足上述要求。在步骤d)期间施加到每单位长度组合件的热量，特别是每单位长度的焊接热量也是因材料而具体明确的，并且取决于许多因数，例如所用焊接方法，待焊接材料的比热容量，其传导性和保持熔化状态以便在局部加热或焊接之后获得良好固结材料所需要的时间。每单位长度的焊接热量可由本领域的技术人员通过实验容易地确定。
在本发明另一个实施例中，提供一种方法，其中将散热片施加到部分植入物，更优选施加到植入物的外部，并且最优选施加在植入物的外缘处。合适的散热片包含通常用作散热片材料、特别是具有相对高比热容量的材料的块状体、带状物、条状物等等。合适的材料包括金属。例如，散热片与植入物的界面可进一步具备热量吸收贴。该散热片在粘合之后被移除。
热固性聚合物部件的植入物优选地包含增强纤维。在本发明的又一个实施例中，提供一种方法，其中植入物包含延伸到热固性聚合物中的增强纤维。这种实施例允许减少焊接热量和/或时间，从而避免在粘合期间降解热塑性和/或热固性聚合物并同时仍获得令人满意的粘合强度。
在本发明的另一方面中，提供一种方法，其用于将热固性聚合物部件粘合至另一个热固性聚合物部件，在该方法中，热塑性聚合物以包含热塑性聚合物的植入物的固化的热固性聚合物部件的形式被提供。
在本发明的另一个方面中，提供一种固化的热固性聚合物部件，其至少在待粘合的热固性聚合物部件的一部分处包含热塑性聚合物的植入物。
在本发明的第一方面的优选实施例中，提供一种方法，其中将植入物设计成使得避免在植入物与热固性聚合物部件的界面处过度加热。
在本发明的另一优选实施例中，提供一种方法，其中热固性聚合物部件包含纤维增强的热固性聚合物复合部件。
根据本发明的方法的另一个优选实施例的特征在于，热固性聚合物部件是堆叠的预浸渍热固性聚合物复合带与包含堆叠的预浸渍热塑性聚合物复合带的植入物的组合件。
根据本发明的方法的另一实施例涉及一种方法，其中待粘合的热塑性聚合物是热塑性聚合物部件或具有可相容热塑性聚合物表面的部件。
根据本发明的方法的另一个优选实施例利用选自熔融温度为至少200℃的工程热塑性聚合物的类别的待粘合的热塑性聚合物和/或植入物的热塑性聚合物。在更优选方法中，待粘合的热塑性聚合物和/或该植入物的热塑性聚合物选自聚醚酰亚胺(PEI)、聚醚醚酮(PEEK)、聚苯硫醚(PPS)、聚醚酮(PEK)、聚醚酮酮(PEKK)和它们的组合或等效物。
根据本发明的方法的另一个实施例的特征在于，待粘合的热塑性聚合物或该植入物的热塑性聚合物包含用于局部加热的导电颗粒。
在根据本发明的方法的实施例中，热固性聚合物包含环氧树脂和/或双马来酰亚胺树脂/硬化剂混合物。
可方便地通过堆叠预浸渍热固性聚合物复合带和堆叠形成植入物的预浸渍热塑性聚合物复合带，制作具有形成粘合性表面的热塑性聚合物的植入物的未固化或部分固化的热固性聚合物部件。热塑性植入物还可通过使用注塑技术现场制作。热固性和热塑性聚合物的共注塑也是可以的。
包含植入物的热固性聚合物部件优选地通过焊接粘合至热塑性聚合物(部件)或另一包含植入物的热固性聚合物部件，或粘合至另一热固性聚合物或热固性聚合物复合物或粘合至热塑性聚合物(复合物)。
优选的焊接技术包括感应焊接、电阻焊接和激光焊接，但不限于此。
在本发明的另一方面中，提供一种具有热塑性表面的固化的热固性聚合物部件与焊接到其上的热塑性聚合物部件的组合件，该热塑性聚合物具有超过热固性聚合物的固化温度的熔融温度。
在本发明的任何上述实施例中，热塑性聚合物植入物和临近该植入物的未固化的热固性聚合物或热固性聚合物复合物能够在被加热时，在热固性聚合物固化之前至少部分互相渗透，从而将热塑性聚合物植入物粘合至热固性聚合物或热固性聚合物复合物。这确保通过植入物给予该热固性聚合物(复合物)的热塑性表面不能从热固性聚合物或热固性聚合物复合物上轻易地移除。
具有热塑性植入物的固化或未固化的热固性聚合物或热固性聚合物复合物可以根据发明方法粘合至其它热塑性聚合物，或可以粘合至具备热塑性植入物的另一热固性聚合物或热固性聚合物复合物。
本发明方法的其它优点在于，当彼此接触放置时，待粘合的熔化热塑性聚合物和该植入物的热塑性聚合物提供高热塑性聚合物流，从而填充待粘合的接触表面中的任何波状起伏或缺陷。通过改变温度和/或通过在加热期间施加更多接触压力至待粘合部件或允许用于粘合的额外时间，可能影响该热塑性流。
本发明的方法的优点还涉及这样的事实，即简单地通过至少部分地再加热该已焊接的热塑性聚合物和热塑性植入物，先前粘合至彼此的部件可在需要时被拆卸并再次重新组装。如果需要，可在待粘合表面之间添加额外热塑性聚合物用于更好的粘合。如果在选定区域中需要，再加热还可用于改进所产生的焊缝的质量。
一般来说，根据本发明的方法将至少在热塑性聚合物植入物与热固性聚合物之间界面处，在高于固化的热固性聚合物或聚合物复合物部件的玻璃化转变温度的温度下进行。然而，粘合可涉及的温度仅稍微高于该温度，或可以甚至接近于热固性聚合物的降解温度。
热固性聚合物(复合物)部件可包含通过根据本发明之外的其它方法粘合到该热固性聚合物(复合物)部件的其它部件，例如金属嵌件，泡沫或蜂窝芯材，热固性部件或膜的热塑塑料，或可包含可作为热固性(复合物)部件的组成部分的任何其它材料。
附图说明
本发明现在将通过举例的方式而非限制于此，并参考附图来更详细地描述，其中∶
图1示出根据本发明的具有热塑性表面的固化的热固性聚合物部件和待焊接到其上的热塑性聚合物部件的第一实施例；
图2表示根据本发明的具有热塑性表面的固化的热固性聚合物部件和待焊接到其上的热塑性聚合物部件的第二实施例；
图3表示根据本发明的具有热塑性表面的固化的热固性聚合物部件和待焊接到其上的热塑性聚合物部件的另一个实施例；和
图4示意性示出将用于本发明的方法中的热塑性植入物的实施例。
具体实施方式
参考图1，示出具有热塑性表面3的固化的热固性聚合物部件2的组合件1的实施例，可根据本发明的方法将热塑性聚合物部件4焊接到该组合件1上。热塑性聚合物部件4的热塑性聚合物具有250℃到400℃之间的熔融温度，其超过用于热固性聚合物部件2中的热固性聚合物的固化温度，所述固化温度范围通常介于室温左右和200℃之间。已经通过一种方法获得组合件1，所述方法包含至少在待粘合的热固性聚合物部件的一部分处（在此实施例中为表面3）提供具有热塑性聚合物的植入物5的未固化或部分固化的热固性聚合物(固化部件2的前体)并且固化该热固性聚合物，因此未固化的热固性聚合物部件2和植入物5的热塑性聚合物至少部分互相渗透。该工艺在热塑性聚合物植入物5和固化的热固性聚合物2之间形成粘合。由于固化的高温，热固性单体实际上可以通过植入物5的热塑性聚合物，特别是通过其结晶域较容易地迁移。以此方式，在这两者之间形成强粘合。明显地，优先选择这样的固化温度和时间周期，使得热固性单体(和硬化剂)能够足够深地迁移到植入物5的熔化聚合物中。可以在不改变用于热固性聚合物2的制造商推荐的固化周期的情况下，向热固性聚合物2提供热塑性植入物5。然而，特别是在热固性聚合物2和植入物5的热塑性聚合物之间的相容性不是最佳时，可能需要略微改变。
根据本发明，使热塑性聚合物(部件)4与至少组合件1的表面3和加热至热塑性聚合物4的熔融温度的热塑性聚合物和热固性聚合物部件接触，因此植入物5的热塑性聚合物熔化并与热塑性聚合物(部件)4融合，换句话说形成热塑性聚合物植入物5和热塑性聚合物(部件)4之间的粘合，所述粘合在冷却热塑性聚合物5和固化的热固性聚合物部件2的组合件1之后固结。
为了避免在粘合过程期间过度加热热固性聚合物，应该根据热塑性植入物5的几何形状选择焊接区域。在图1中，可焊接区域示意性地以区域6示出。可在热塑性聚合物4和5之一或两者的熔融温度下完成该区域6内的加热。这些聚合物4和5优选地具有相差仅20℃，更优选相差15℃并最优选相差仅10℃的熔融温度。优选地，热塑性聚合物4和5是大体上相同的聚合物。在热固性聚合物2的固化期间，优选地通过形成半互相渗透聚合物网络，将植入物5的热塑性聚合物粘合至热固性聚合物2的内表面(如图1中所示实例)或外表面(如图2中所示实例)。为此目的，热塑性聚合物5优选地与热固性聚合物2的所选热固性单体相容。聚合物科学领域的技术人员具有足够的工具供其使用，例如熟知的热力学和溶解度标准。
使用根据本发明的方法可实现的典型粘合强度超过30MPa，更优超过35MPa，并且最优选超过40MPa(双搭接接头强度测试)。
典型焊接压力的范围为50kPa至1MPa，并且优选的是100kPa至350kPa的范围。然而，当不施加压力时，根据本发明的方法也可提供良好粘合，但还可使用超过1MPa的压力，尽管这种压力可能导致熔化热塑塑料的某些挤出。
图中示出具有热塑性表面3的固化的热固性聚合物部件2的组合件1的另一个实施例，图2中示出可根据本发明的方法焊接至其上的热塑性聚合物部件4。在此情况下，热塑性聚合物植入物5实际上粘合至热固性聚合物部件2的外表面。然而，根据本发明其功能依旧，因为设定植入物5的尺寸，使得当将可焊接区域限制到区域6时，避免热固性聚合物在与植入物5的界面处过度加热。
具备热塑性聚合物植入物5的热固性聚合物2在外部热量和压力的提供下（例如加热板）可接合到热塑性部件4。或者，可以使用掺入待粘合的部件内的局部加热元件或甚至可加热材料，允许热量集中于焊接区域6。
因为在根据本发明的方法中，在高于热塑性聚合物4和5的熔化温度下进行加热，这些热塑塑料将在焊接期间，甚至在相对低焊接压力下显示大量流动。该流动允许热塑塑料4和5填充其表面中小的不平整或者甚至是待焊接的部件2和4之间的相对小的间隙。
图中示出具有热塑性表面3的固化的热固性聚合物部件2的组合件1的另一个实施例，图3中示出可根据本发明的方法焊接至其上的热塑性聚合物部件4。在此情况下，热塑性聚合物植入物5具备设置在其外缘处的两个散热片10和11。设定植入物5的尺寸，使得当将可焊接区域限制到区域6时，限制热固性聚合物2在与植入物5的界面7处的加热，使得不超过热固性聚合物的最大操作温度。散热片10和11吸收一部分焊接热量。通过使用多层热量吸收贴8，向植入物5提供散热片10和11。通过使用与接触区域6内的焊接部分4接触的焊1枪9将具备热塑性聚合物植入物5的热固性聚合物2接合到热塑性部件4。
图4最终示出本发明的方法中使用的优选植入物的示意性侧视图。在所示实施例中，提供热塑性聚合物的植入物，其包含随后进一步延伸至植入物5的边界(50,51)的连续增强纤维12。当将这种植入物与热固性聚合物部件固结时，纤维12的自由(干燥)部分将延伸到热固性聚合物中，其中这些纤维部分将与热固性聚合物一起被润湿并且一旦固化则与热固性聚合物部件相结合。结果表明，根据该实施例的植入物特别适用于本发明的方法，因为其允许得到令人满意的粘合强度，而且还限制在粘合期间施加的热量。
根据本发明的方法还允许不焊接以及分离先前焊接的部件2和4。其中的部件(2,4)被加热到高于热塑性聚合物(4,5)的熔化温度的温度，并且两个部件(2,4)至少部分地分离，这需要有限的力。因为各部件(2,4)大体上保持其大部分的表面性质，分离的部件可以随后根据发明方法被再次焊接。如果需要，在热塑性材料不足够用于良好粘合的情况下，可以在待粘合的热塑性表面之间添加额外的热塑性材料。
根据本发明粘合的组合件1还可以提供额外的优点，例如改进的耐化学性，改进的耐磨和耐腐蚀性，改进的生物相容性，改进的摩擦性等等。
可以理解的是在说明书中公开的本发明仅是通过举例方式给出，本领域技术人员可以在所附权利要求书的范围内设想出许多变型。

Claims (12)

1.一种用于将热塑性聚合物粘合至热固性聚合物部件的方法，所述方法包含以下步骤：
a)提供热塑性聚合物，
b)提供固化的热固性聚合物部件，其至少在待粘合的所述热固性聚合物部件的一部分处包含热塑性聚合物的植入物，
c)使所述热塑性聚合物与至少待粘合的所述部分接触定位，
d)至少在接触的区域中将所述热塑性聚合物和热固性聚合物部件加热至所述热塑性聚合物的熔融温度，因此所述热塑性聚合物的植入物熔化并与所述热塑性聚合物融合；以及
e)冷却所述热塑性聚合物和固化的热固性聚合物部件的组合件，使得所述热塑性聚合物粘合至所述固化的热固性聚合物部件，
其中所述热塑性聚合物的熔融温度至少为200℃，超过所述热固性聚合物部件的固化温度的熔融温度，其中为熔化待粘合的所述热塑性聚合物和所述热塑性聚合物的植入物所施加的热量大体上分布于待焊接的界面处，并且其中通过在热粘合期间通过焊接来保持所述热塑性聚合物的植入物中的温度梯度，使得即便在高于所述热固性聚合物的降解温度下加热时，在所述热塑性聚合物的植入物与所述热固性聚合物部件的所述界面处的所述温度足够低以大体上不降解所述热固性聚合物部件，并且通过向所述热塑性聚合物的植入物的一部分施加在粘合之后被移除的散热片，而将所述热塑性聚合物的植入物设计成使得在粘合步骤d)期间，在所述热塑性聚合物的植入物与所述热固性聚合物部件的所述界面处，避免在高于所述热固性聚合物部件的最大操作温度下加热。
2.根据权利要求1所述的方法，其中所述散热片在被外部施加至所述热塑性聚合物的植入物。
3.根据权利要求1所述的方法，其中在所述热塑性聚合物的植入物的外缘处施加所述散热片。
4.根据权利要求1所述的方法，其中所述热塑性聚合物的植入物包含延伸到所述热固性聚合物部件中的增强纤维。
5.根据权利要求1所述的方法，其中以包含所述热塑性聚合物的植入物的固化的热固性聚合物部件的形式提供所述步骤a)中的热塑性聚合物。
6.根据权利要求1所述的方法，其中通过提供固化温度低于所述热塑性聚合物的所述熔融温度的未固化或部分固化的热固性聚合物部件，并且将所述热塑性聚合物的植入物的所述热塑性聚合物和热固性聚合物部件加热至所述热固性聚合物的所述固化温度，因此所述未固化或部分固化的热固性聚合物部件和所述热塑性聚合物的植入物的所述热塑性聚合物至少部分互相渗透，获得包含所述热塑性聚合物的植入物的所述步骤b)中的固化的热固性聚合物部件。
7.根据权利要求1所述的方法，其中所述热固性聚合物部件包含纤维增强的热固性聚合物复合部件。
8.根据权利要求1所述的方法，其中待粘合的所述热塑性聚合物为热塑性聚合物部件或具有可相容热塑性聚合物表面的部件。
9.根据权利要求1所述的方法，其中待粘合的所述热塑性聚合物和/或所述热塑性聚合物的植入物的热塑性聚合物选自熔化温度为至少200℃的工程热塑性聚合物类。
10.根据权利要求9所述的方法，其中待粘合的所述热塑性聚合物和/或所述热塑性聚合物的植入物的热塑性聚合物选自聚醚酰亚胺(PEI)、聚醚醚酮(PEEK)、聚苯硫醚(PPS)、聚醚酮(PEK)、聚醚酮酮(PEKK)和它们的组合或等效物。
11.根据权利要求1所述的方法，其中待粘合的所述热塑性聚合物或所述热塑性聚合物的植入物的热塑性聚合物包含用于局部加热的导电粒子。
12.一种具有热塑性表面的固化的热固性聚合物部件与焊接到其上的热塑性聚合物部件的组合件，其中所述热塑性聚合物部件的熔融温度至少为200℃，超过所述热固性聚合物部件的固化温度的熔融温度；并且，其中所述热固性聚合物部件在焊接后不会显著的降解。
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