CN103963290A - 激光焊接方法 - Google Patents

激光焊接方法 Download PDF

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Publication number
CN103963290A
CN103963290A CN201410043762.XA CN201410043762A CN103963290A CN 103963290 A CN103963290 A CN 103963290A CN 201410043762 A CN201410043762 A CN 201410043762A CN 103963290 A CN103963290 A CN 103963290A
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Prior art keywords
laser
angle
welding
sealing wire
composition surface
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佐藤正和
提坂裕至
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Koito Manufacturing Co Ltd
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Koito Manufacturing Co Ltd
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Publication of CN103963290A publication Critical patent/CN103963290A/zh
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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
    • 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
    • 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
    • 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
    • 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
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • 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
    • B29C66/301—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
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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
    • B29C66/54—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
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/812—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 composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/8126—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 composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/81266—Optical properties, e.g. transparency, reflectivity
    • B29C66/81267—Transparent to electromagnetic radiation, e.g. to visible light
    • 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
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/20—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by refractors, transparent cover plates, light guides or filters
    • F21S41/29—Attachment thereof
    • 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
    • B29C65/78—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
    • B29C65/7802—Positioning the parts to be joined, e.g. aligning, indexing or centring
    • 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
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    • 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
    • B29C66/70—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
    • 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
    • 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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    • B29C66/814—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
    • B29C66/8141—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 surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81411—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 surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat
    • B29C66/81421—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 surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave
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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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    • B29C66/8141—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 surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)
  • Electromagnetism (AREA)
  • Health & Medical Sciences (AREA)
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  • General Engineering & Computer Science (AREA)
  • Thermal Sciences (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Laser Beam Processing (AREA)

Abstract

一种激光焊接方法，其向接合面的各部提供均匀的激光能量，以短时间高效地组装高气密性的树脂成形品。在车辆用灯具（1）的本体（2）和透镜（3）的激光焊接中，首先，将本体（2）和透镜（3）以接合状态组装，向具有检流计镜（15）的激光头（13）定位。接着，利用镜（15）沿着焊接线（4）扫描激光（6），利用激光能量焊接本体（2）和透镜（3）的接合面（5）。接合面（5）包括：使激光（6）以第一角度射入的第一部位（A）和使激光（6）以比第一角度大的第二角度射入的第二部位（B）。在焊接工序中，控制激光光源（12）的输出，使第一部位（A）和第二部位（B）双方接收大致等量的激光能量。

Description

激光焊接方法
技术领域
本发明涉及一种激光焊接方法，其通过镜的位移扫描激光，焊接树脂成形品的接合面。
背景技术
以往，已知有利用具有检流计镜（ガルバノミラー）的激光头焊接车辆用灯具的本体和透镜的接合面的方法。例如，专利文献1所述的焊接方法包括：将灯具本体和透镜在相互接合的状态下向电流式激光头定位的工序；通过镜沿着焊接线扫描激光，利用激光能量焊接接合面的工序。
现有技术文献
专利文献
专利文献1：日本特开2011-102029号公报
发明内容
发明要解决的技术问题
电流式激光焊接法通过控制镜的角度，使激光以高速多次进行照射，能够将灯具本体和透镜的焊接面整周大致同时地熔融。因此，即使在激光照射前由于接合面的凹凸、本体或者透镜的成形后的变形等存在间隙的情况下，也通过破坏凹凸部，能够在激光照射后制作无缝隙的高气密性的车辆用灯具。此外，由于树脂成形品的尺寸精度的允许幅度变宽，所以还具有模型规格的简单化、伴随着整套取出的成形加工费的削减等优点。
但是，根据以往的电流式激光焊接方法，将激光头（电流头）固定在设备，仅对头内的镜进行角度控制，因此伴随着镜的角度控制，激光在圆锥面内移动，倾斜地射入到树脂成形品的接合面。于是，激光的一部分在工具、树脂成形品的界面反射，接合面接收的激光能量降低。特别是，在结合面为三维形状的情况下，由于激光的射入角在连续地变化，根据接合面的部位，接收的激光能量大小变动，存在在能量不足的部位发生焊接不良的问题。
图4是表示以往的激光焊接方法导致的问题点的示意图。示意图A、B表示灯具本体51和透镜52的接合面上不同的部位53A、53B。激光54从电流头（省略图示）以总是恒定的强度射出，伴随着镜的角度控制，在部位53A以相对浅的角度（例如θa=20°）射入，在部位53B以相对深的角度（例如θb=60°）射入。在图中，箭头以面积表示激光54具有的能量的大小。
在示意图A的情况下，激光54首先在工具55的射入面反射而失去能量E1，然后在工具55的射出面反射而失去能量E2，接着在透镜52的表面（外观面）反射而失去能量E3，在此之后在本体51和透镜52的接合面反射而失去能量E4。在射入角小的部位53A，由于各反射面上能量损失量较少，因此部位53A接收的能量E5的大小（能量透过率）是到达工具55之前的初期能量E0的85.8%左右，如果各部均等地获得这种程度的能量大小，则接合面整体的焊接状态变得良好。
但是，如示意图B所示，在射入角大的部位53B，激光54依次在工具55的射入面、工具55的射出面、透镜52的表面、本体51和透镜52的接合面反射，伴随着各面的反射损失较多的能量E1、E2、E3、E4。其结果是，部位53B接收的能量E5的大小降低至初期能量E0的69.9%，发生能量不足。如果为了避免能量不足而整体地设高激光输出，则能量充足的其他部位受到必要以上的破坏，在该部位产生多余的毛刺部。
此外，为了避免焊接不良，专利文献1提出了根据激光的射入角度控制检流计镜的扫描速度的技术（参照第0043段）。但是，根据控制扫描速度的方法，特别是在树脂成形品的接合面是三维形状的情况下，对应一周的扫描时间变长，伴随着激光的连续旋转扫描的焊接工序消耗大量时间，存在树脂成形品的组装效率降低的问题。
本发明旨在提供一种激光焊接方法，其能够向接合面的各部提供均匀的激光能量，在短时间高效地组装高气密性的树脂成形品。
解决技术问题的技术方案
为了解决上述技术问题，本发明提供如下所述的激光焊接方法。
（1）一种激光焊接方法，其特征在于，包括：预备工序，相对具有扫描激光的镜的激光头，将相互接合的两个树脂成形品进行定位；焊接工序，利用镜沿着树脂成形品的焊接线扫描激光，以激光能量焊接树脂成形品的接合面，树脂成形品的接合面包括：第一部位，其使激光以第一角度射入；第二部位，其使激光以比第一角度大的第二角度射入，焊接工序包括控制激光强度的阶段，使第一部位和第二部位接收大致等量的激光能量。
（2）一种激光焊接方法，其特征在于，树脂成形品的焊接线在该成形品的周缘部以环状被设定，控制激光强度的阶段包括在焊接线上的至少两点切换激光光源的输出的步骤。
（3）一种激光焊接方法，其特征在于，控制激光强度的阶段包括：基于接合面的形状，求出在第一、第二部位的激光的射入角的步骤；根据该射入角的大小，决定向第一、第二部位射出的激光的强度的步骤。
（4）一种激光焊接方法，其特征在于，控制激光强度的阶段包括：使照射第一、第二部位的激光的强度与镜的方向产生关联并且进行记忆的步骤。
（5）一种激光焊接方法，其特征在于，控制激光强度的阶段包括：使照射第一、第二部位的激光的强度与焊接线上的两个位置产生关联并且进行记忆的步骤。
发明的效果
本发明的激光焊接方法具有下述效果：由于控制激光的强度，使射入角度大的部位和小的部位接收大致等量的激光能量，因此，能够向接合面的各部提供均匀的激光能量，以短时间高效地组装高气密性的树脂成形品。
附图说明
[图1]图1是表示本发明的一个实施方式的激光焊接系统的示意图。
[图2]图2是由图1的系统执行的激光焊接方法的工序图。
[图3]图3是表示图2的激光焊接方法的作用效果的示意图。
[图4]图4是表示以往的激光焊接方法的问题点的示意图。
符号的说明
1车辆用灯具2本体3透镜4焊接线5接合面6激光7工具11激光焊接系统12激光光源13激光头14控制装置15检流计镜
具体实施方式
下面，基于附图说明本发明的一个实施方式。图1所示的激光焊接系统11用于车辆用灯具1的本体2和透镜3的焊接。本体2由ASA、ABS等光吸收性树脂成形，而透镜3由丙烯酸树脂（アクリル）、聚碳酸酯（ポリカーボネート）等光透过性树脂成形。在车辆用灯具1的周缘部设有环状的焊接线4，本体2和透镜3的接合面5被激光6沿着焊接线4被焊接。
在激光焊接系统11中设有激光光源12、激光头13、控制装置14。激光头13内置有：检流计镜15（在图中表示多个中的一个），其被固定设置在灯具生产设备，用于在X、Y方向上扫描激光6；光学系统（省略图示），其在Z轴方向上调整激光6的焦点位置。控制装置14控制激光光源12的输出、镜15的方向、焦点位置，从而能够沿着焊接线4三维地扫描激光6。
如图2所示，本实施方式的激光焊接方法包括预备工序（S20）和焊接工序（S30）。在预备工序中，利用工具7（参照图3）将本体2和透镜3组装成相互接合的状态，向具有镜15的激光头13定位。在这里，如图1所示，本体2和透镜3的接合面5是与车体外表面相适应的三维形状，在焊接线4设有距离激光头13的激光射出部相对远的部位4a和相对近的部位4b。
如图2所示，在焊接工序，利用检流计镜15沿着焊接线扫描激光6，利用激光能量焊接本体2和透镜3的接合面5。具体地，首先，基于接合面5的形状，通过目测或者控制装置14的计算功能求出在接合面5的至少两个部位的激光6的射入角，根据射入角的大小，决定照射各部位的激光6的强度（S31）。
在这里，如图3所示，作为接合面5的部位，可例示有以第一角度（θa）射入激光6的第一部位5A和以比第一角度大的第二角度（θb）射入激光6的第二部位5B。在图1所示的车辆用灯具1的情况下，焊接线4上的部位4a与第一部位5A对应，使激光6从头13以相对浅（小）的角度射入，焊接线4上的部位4b与第二部位5B对应，使激光6以相对深（大）的角度射入。
一旦决定了激光6的强度，接着，使激光头13向第一以及第二部位5A、5B射出的激光6的强度与检流计镜15的方向（倾动角度）产生关联，在控制装置14的存储部记忆（S32）。或者，使向部位5A、5B射出的激光6的强度与包括焊接线上的部位4a、部位4b的多个位置产生关联，进行记忆（S33）。这样，能够高速且连续地进行激光6的周回扫描。
在旋转扫描的过程中，控制装置14在焊接线4上的至少两点切换激光光源12的强度（S34）。由此，例如图1所示，在激光6从焊接线4上的部位4a移动到部位4b的点17，激光光源12的输出从“低”切换为“高”，在从部位4b移动到部位4a的点18，光源12的输出从“高”切换为“低”。虽然在图1中例示了两个切换点17、18，但是在射入角度的变动幅度大的接合面5能够进一步增加切换点的数目。此外，在射入角度急剧变化的多个点，还可以将激光6的强度阶段地切换，或者，与接合面5的三维形状相适应地连续切换激光6的强度。
通过以上的步骤（S31～S34），在焊接工序，激光6的强度被控制为在射入角度大的部位和小的部位接收大致等量的能量（S35）。例如，如图3所示，将照射部位5B时的激光光源12的输出增强为比部位5A时大23%，从而使射入角度浅（θa=20°）的部位5A和射入角度深（θb=60°）的部位5B接收等量的能量E0。
这样，在射入角度深的部位5B，补充伴随着激光6的反射的能量损失量（E1+E2+E3+E4），与射入角度浅的部位5A相同地，能够将能量透过率提高至初期能量E0的85.8%。其结果是，在接合面5的各部提供均匀的激光能量，使灯具整周的接合面5以良好的状态密接，能够制作高气密性的车辆用灯具1。此外，与利用速度控制的方法相比，能够始终进行激光6的连续旋转扫描，缩短焊接工序时间，能够高效地组装车辆用灯具1。
此外，本体2以及透镜3仅仅是树脂成形品的一个例子。也可以将本发明的方法适用在反射器、延伸部的激光焊接，或者应用于车辆用灯具以外的各种树脂成形品。此外，能够以手动、自动的任一种方式进行激光光源12的输出控制，能够利用传感器探测激光6的射入角。除此之外，在不超出本发明的主旨的范围内，能够适当地变更各部的构成、步骤而进行实施。

Claims (6)

1.一种激光焊接方法，其特征在于，包括：
预备工序，相对具有扫描激光的镜的激光头，将相互接合的两个树脂成形品进行定位；
焊接工序，利用所述镜沿着树脂成形品的焊接线扫描激光，以激光能量焊接树脂成形品的接合面，
所述树脂成形品的接合面包括：第一部位，其使激光以第一角度射入；第二部位，其使激光以比第一角度大的第二角度射入，
焊接工序包括控制激光的强度的阶段，使第一部位和第二部位接收大致等量的激光能量。
2.根据权利要求1所述的激光焊接方法，其特征在于，所述焊接线在树脂成形品的周缘部以环状被设定，所述控制阶段包括在焊接线上的至少两点切换激光光源的输出的步骤。
3.根据权利要求1或者2所述的激光焊接方法，其特征在于，所述控制阶段包括：基于接合面的形状，求出在第一、第二部位的激光的射入角的步骤；根据该射入角的大小，决定向第一、第二部位射出的激光的强度的步骤。
4.根据权利要求3所述的激光焊接方法，其特征在于，所述控制阶段包括：使照射第一、第二部位的激光的强度与镜的方向产生关联并且进行记忆的步骤。
5.根据权利要求3所述的激光焊接方法，其特征在于，所述控制阶段包括：使照射第一、第二部位的激光的强度与焊接线上的两个位置产生关联并且进行记忆的步骤。
6.根据权利要求4所述的激光焊接方法，其特征在于，所述控制阶段包括：使照射第一、第二部位的激光的强度与焊接线上的两个位置产生关联并且进行记忆的步骤。
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Application publication date: 20140806