CN104999661A - 一种激光同步焊接工艺及装置 - Google Patents

一种激光同步焊接工艺及装置 Download PDF

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CN104999661A
CN104999661A CN201510452594.4A CN201510452594A CN104999661A CN 104999661 A CN104999661 A CN 104999661A CN 201510452594 A CN201510452594 A CN 201510452594A CN 104999661 A CN104999661 A CN 104999661A
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welding
light pipe
product
laser
product base
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CN104999661B (zh
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郭肇基
杨晓锋
忻国祥
黄海
王永和
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Shanghai Xinyao Electronics Co Ltd
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Shanghai Xinyao Electronics Co Ltd
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Priority to EP16161730.3A priority patent/EP3117979B1/en
Priority to US15/077,234 priority patent/US10144090B2/en
Priority to JP2016057256A priority patent/JP6105781B2/ja
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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
    • B29C65/1603—Laser beams characterised by the type of electromagnetic radiation
    • B29C65/1612—Infrared [IR] radiation, e.g. by infrared lasers
    • 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
    • B29C65/1664—Laser beams characterised by the way of heating the interface making use of several radiators
    • B29C65/1667—Laser beams characterised by the way of heating the interface making use of several radiators at the same time, i.e. 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
    • 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
    • B29C65/1687—Laser beams making use of light guides
    • 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
    • B29C65/7841—Holding or clamping means for handling purposes
    • 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
    • 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
    • B29C66/301—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
    • 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
    • B29C66/51—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
    • 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
    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/82—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps
    • B29C66/824—Actuating mechanisms
    • B29C66/8242—Pneumatic or hydraulic drives
    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • 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
    • B29C65/1677—Laser beams making use of an absorber or impact modifier
    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—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
    • 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
    • B29C66/8122—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 composition of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/747—Lightning equipment

Abstract

本申请提供了一种激光同步焊接工艺及装置，涉及激光焊接技术领域，通过利用运动下模和固定上模使得产品底座与产品透镜贴合后，利用诸如透明物体等廉价材质制备的导光管，将激光源发射的激光束经处理后透过产品透镜照射至产品底座的焊接区域中，进而对焊接区域进行快速、均匀加热；同时，利用焊接气缸对产品底座及产品透镜进行压合，使得产品底座及产品透镜在熔融状态下压合焊接在一起，且焊接时在不产生粉末等缺陷的同时还能使得焊接所产生的废边尺寸的高度H和宽度w均在[0，0.4mm]之间，即能够有效的提高焊接产品的性能。

Description

一种激光同步焊接工艺及装置
技术领域
本发明涉及激光焊接技术领域，尤其涉及一种激光同步焊接工艺及装置。
背景技术
激光焊接是利用高能量密度的激光束作为热源的一种高效精密焊接方法，其主要用于焊接薄壁材料和低速焊接，由于其焊接过程属热传导型，即激光辐射加热工件表面，表面热量通过热传导向内部扩散，通过控制激光脉冲的宽度、能量、峰值功率和重复频率等参数，能够使得工件熔化，以形成特定的熔池。
目前，在车灯行业塑料件大灯或后灯的焊接过程中，一般是采用激光焊接工艺来进行物件之间的焊接，但在实际应用中却发现当前的激光焊接工艺中，焊接时焊接筋焊接状态不稳定，且由于焊接时激光束是通体震镜反射到被焊接物体上，而被焊接物体又多是曲面形状角度等不规则图形，就会使得激光发生器照射时产生反射等缺陷，进而使得激光的能量被部分反射掉，即激光的能量不能全部集中在被焊接物体上(激光器发射端面不再被焊接物焊接的法线上)；进而致使焊接不稳定。
发明内容
鉴于上述问题，本申请记载了一种激光同步焊接装置，可应用于对被焊接物进行同步焊接的工艺中，所述被焊接物包括产品底座和产品透镜，所述装置包括：
顶升气缸；
第一承载板，固定设置于所述顶升气缸之上；
第二承载板，通过焊接气缸设置于所述第一承载板之上；
运动下模，固定设置于所述第二承载板之上，以用于夹持所述产品底座；
固定上模，对应所述运动下模设置于所述运动下模的上方，以用于夹持所述产品透镜；以及
所述固定上模之上设置有激光源和导光管，且所述导光管位于所述激光源与所述产品透镜之间；并且
所述顶升气缸通过所述第一承载板和所述第二承载板驱动所述产品底座移动至焊接点位置处，以使所述产品透镜贴合至所述产品底座之上；所述导光管对所述激光源发射的激光束进行处理后透过所述产品透镜汇聚至所述产品底座的焊接区域进行加热，同时所述焊接气缸通过所述第二承载板驱动所述运动下模对所述产品底座和所述产品透镜进行压合。
作为一个优选的实施例，上述的激光同步焊接装置中：
所述运动下模上固定设置有产品胎具，且所述产品底座固定设置于所述产品胎具上。
作为一个优选的实施例，上述的激光同步焊接装置中：
所述导光管包括导光管本体和导光管固定块，所述导光管固定块固定于所述固定上模之上；以及
所述激光源发射的激光束经所述导光管本体处理后至所述产品底座的焊接区域进行加热。
作为一个优选的实施例，上述的激光同步焊接装置中：
所述固定上模上设置有若干固定孔；以及
所述导光管本体通过所述若干固定孔固定于所述固定上模上，以形成与所述被焊接物上的所述焊接区域匹配的结构形状。
作为一个优选的实施例，上述的激光同步焊接装置中：
所述导光管本体为管状结构；以及
所述激光源发射的激光束经所述导光管本体处理后分布均匀的条状焊接光斑，所述焊接光斑照射至所述被焊接物的焊接区域进行加热。
作为一个优选的实施例，上述的激光同步焊接装置中：
所述导光管本体的材质为透明材质。
本申请还记载了一种激光同步焊接工艺，可应用于对包括产品底座和产品透镜的焊接物进行焊接，所述工艺包括：
将所述产品底座固定于设置在运动下模上的产品胎具之上，并继续外形定位；
将所述产品透镜夹持于固定上模上，以使所述产品透镜位于所述产品底座的上方；
利用顶升气缸驱动所述产品底座移动至焊接点位置处，使所述产品透镜与所述产品底座贴合；
激光源发射激光束经导光管整形并透过所述产品透镜汇聚至所述产品底座的焊接区域进行加热；同时，利用焊接气缸驱动所述运动下模对所述产品底座和所述产品透镜进行压合。
作为一个优选的实施例，上述的激光同步焊接工艺中：
所述导光管包括导光管本体和导光管固定块，所述导光管固定块固定于所述固定上模之上；以及
所述激光源发射的激光束经所述导光管本体处理后至所述产品底座的焊接区域进行加热。
作为一个优选的实施例，上述的激光同步焊接工艺中：
所述固定上模上设置有若干固定孔；以及
所述导光管本体通过所述若干固定孔固定设置于所述固定上模上，以形成与所述产品底座上的所述焊接区域匹配的结构形状。
作为一个优选的实施例，上述的激光同步焊接工艺中：
所述导光管本体为管状结构；以及
所述激光源发射的激光束经所述导光管本体整形为条状光斑，所述焊接光斑照射至所述产品底座的焊接区域进行加热。
作为一个优选的实施例，上述的激光同步焊接工艺中：
所述导光管本体的材质为透明材质。
作为一个优选的实施例，上述的激光同步焊接工艺中：
采用所述激光同步焊接工艺对所述被焊物进行焊接工艺时，不产生粉末，且所产生的废边的尺寸：
0＜H＜0.4mm；
0＜w＜0.4mm；
所述H为所述废边的高度，所述w为所述废边的宽度。
上述技术方案具有如下优点或有益效果：
本申请中记载的一种激光同步焊接工艺及装置，通过利用运动下模和固定上模使得产品底座与产品透镜贴合后，利用诸如聚碳酸酯或玻璃等廉价材质制备的导光管，将激光源发射的激光经处理后透过产品透镜照射至产品底座的焊接区域中，进而对焊接区域进行快速、均匀加热；同时，利用焊接气缸对产品底座及产品透镜进行压合，使得产品底座及产品透镜在熔融状态下压合焊接在一起，且焊接时在不产生粉末等缺陷的同时还能使得焊接所产生的废边(即飞边)尺寸小于0.4mm，即能够有效的提高焊接产品的性能。
附图说明
参考所附附图，以更加充分的描述本发明的实施例。然而，所附附图仅用于说明和阐述，并不构成对本发明范围的限制。
图1为对热塑性材料进行激光焊接工艺的示意图；
图2为本申请实施例中激光同步焊接装置的结构示意图；
图3为图2中固定上模上设置导光管的结构示意图；
图4为图2中固定上模的结构示意图；
图5为导光管的结构示意图；
图6为本申请实施例中激光同步焊接工艺的流程示意图。
具体实施方式
本发明实施例中提供的激光同步焊接工艺及装置，可基于传统的激光同步焊接工艺及装置的基础上，通过采用透明耐高温的廉价材质制作导光管，使得激光源发射的光线经处理后形成焊接光斑，以对被焊接物进行焊接工艺，具体的可通过利用运动下模和固定上模使得产品底座与产品透镜贴合后，利用廉价透明材质制备的导光管，将激光源发射的激光处理后透过产品透镜照射至产品底座的焊接区域中，进而对焊接区域进行快速、均匀加热；同时，利用焊接气缸对产品底座及产品透镜进行压合，使得产品底座及产品透镜在熔融状态下压合焊接在一起，且焊接时在不产生粉末等缺陷的同时还能使得焊接所产生的废边尺寸高度和宽度均能够小于0.4mm，即能够有效的提高焊接产品的性能。
下面结合附图和具体实施例对本申请的激光同步焊接工艺及装置进行详细说明。
由于激光透射焊接工艺(即透射性红外焊接工艺)的焊接强度符合基体材料强度范围，同时又具有诸如非接触式的灵活焊接工艺、待焊接的部件承受最少的热应力、机械压力小、无粉尘溢料、无震动作业、焊接外观美观、高度精密、焊接强度高、无模具损耗等优点，使得其能够适用许多的热塑性塑料进行焊接。
在进行激光透射焊接工艺(即透射性红外焊接工艺)时，对于被焊接物的材料组合有一定的光学属性要求，即其中的一个结合部件必须对激光透明，一般来说本色状态下的热塑性塑料对于激光束是透明，而另一个则必须吸收所有的激光能量，如使用添加材料(如碳黑)至热塑性材料中便可达到吸收能量效果，且要求在基底材料强度范围内实行焊接强度。
图1为对热塑性材料进行激光焊接工艺的示意图；如图1所示，当采用激光透射焊接工艺(即透射性红外焊接工艺)对热塑性塑料进行焊接时，通常使得激光源11发射的激光束经导光管12处理后透过透明工件(即产品透镜)13照射至激光吸收工件(即产品底座)14上形成能量分布均匀的焊接光斑15，以对激光吸收工件的焊接区域进行局部加热熔融，进而使得透明工件13与激光吸收工件14被焊接在一起，即上述的激光束穿透透明物体(即透明工件13)照射至激光吸收工件14上，以吸收激光能量进而产生热能，而在激光焊接过程中由于两层工件(即透明工件13和激光吸收工件14)通过夹具压紧在一起，热能就从激光吸收工件14传导到透明工件13上，从而使得压紧在一起的两个工件焊接区域熔化并且结合，同时由于塑料本身的热膨胀及热扩张等性能，就会产生内部的压力，内部的压力和外部夹具压力同时作用，能够确保压紧贴合的两个工件能够牢固焊接。
图2为本申请实施例中激光同步焊接装置的结构示意图，图3为图2中固定上模上设置导光管的结构示意图，图4为图2中固定上模的结构示意图，图5为导光管的结构示意图；如图2～5所示，可基于图1所示的结构及相关阐述的基础上，本实施例提供了一种激光同步焊接装置，可应用于对被焊接物进行同步焊接的工艺中，被焊接物包括产品底座(即激光吸收工件14)和产品透镜(即透明工件13)，上述的焊接装置包括：
顶升气缸1，可固定设置于行业中进行工艺特制平台上，且该顶升气缸1的数量可为一个或多个，只要使得设置在其上的部件能够保持水平或工艺要求的参数范围内即可。优选的，该顶升气缸1可为业界常用的用于顶升部件上下运动气缸，如该顶升气缸1可包括有缸筒、端盖、活塞、活塞杆和密封圈等部件。
第一承载板2，可固定设置于上述顶升气缸1之上，以用于在该第一承载板2的顶部表面上设置后续的激光同步焊接工艺的其他部件结构；例如，可将该第一承载板2平躺着固定设置于上述顶升气缸1的活塞杆的顶端，以在顶升气缸1进行工作(如顶起)时驱动第一承载板2及其上设置的部件结构进行上下运动，且第一承载板1在上下运动时保持板面的水平不变进行垂直方向的上下运动。
第二承载板4，可通过焊接气缸3(该焊接气缸3也可为包括有缸筒、端盖、活塞、活塞杆和密封圈等部件的气缸)设置于上述第一承载板2的上方；相应的，第二承载板4在上下运动时也保持板面的水平不变进行垂直方向的上下运动。
运动下模5，固定设置于在上述的第二承载板4的顶部表面上，以用于夹持上述的产品底座；例如，可通过在该运动下模5上设置产品胎具，而上述的产品底座则可固定设置(如夹持)于该产品胎具上，以驱动产品底座进行运动。
固定上模6，则对应上述的运动下模5的位置处设置在运动下模5的上方，以夹持上述的产品透镜；例如，该固定上模6可固定设置在模架7之上，使得固定上模6设置在运动下模5的上方，以使得产品透镜与产品底座对准。
进一步的，上述的固定上模6之上设置有激光源11和导光管12，且该导光管12位于上述的激光源11与产品透镜(即透明工件13)之间。
在进行激光焊接工艺时，顶升气缸1通过第一承载板2和第二承载板4驱动运动下模5带动固定其上的产品底座(即激光吸收工件14)移动至预设的焊接点位置处(可根据具体的工艺需求及焊接工艺结构参数来设定)，以使固定在固定上模6上的产品透镜(即透明工件13)与产品底座(即激光吸收工件14)贴合；上述的导光管12对激光源11发射的激光束进行处理并透过产品透镜(即透明工件13)汇聚至产品底座(即激光吸收工件14)的焊接区域上形成焊接光斑15以进行加热预定时间，即只要能够使得被焊接物呈现熔融状态实现焊接即可，以使得产品底座(即激光吸收工件14)的焊接区域及与产品底座(即激光吸收工件14)接触的产品透镜(即透明工件13)的区域均被加热呈现熔融状态，同时，利用上述的焊接气缸3通过第二承载板驱动4及运动下模5对产品底座(即激光吸收工件14)和产品透镜(即透明工件13)进行压合，以使得产品透镜(即透明工件13)与产品底座(即激光吸收工件14)焊接在一起。
优选的，如图5所示，上述的导光管包括相互固定连接的导光管本体62和导光管固定块63，且导光管固定块63固定于上述固定上模6之上，以使得激光源11发射的激光束经导光管本体62处理后至上述产品底座的焊接区域进行加热。
优选的，如图3～5所示，上述的固定上模6上可设置有若干固定孔61，以用于通过螺栓等固定部件将导光管本体62固定于固定上模6之上，且固定后的导光管本体62的形状与被焊接物上的焊接区域匹配，以使得经该导光管本体62处理后的激光束能够对焊接区区域进行均匀、快速的加热。
优选的，上述的导光管本体62可为管状结构，以使得激光源11发射的激光束经导光管本体62处理后形成焊接光斑15，即该焊接光斑15照射至被焊接物的焊接区域进行加热；上述的导光管本体62的材质可为常规的透明耐高温的材料。
图6为本申请实施例中激光同步焊接工艺的流程示意图；本申请中还提供了一种激光同步焊接工艺，可基于上述激光同步焊接装置的基础上对被焊接物进行焊接工艺，上述的被焊接物包括产品底座(即激光吸收工件14)和产品透镜(即透明工件13)，参见图1～6可知，上述的焊接工艺包括：
首先，将产品底座(即激光吸收工件14)固定于设置在运动下模5上的产品胎具之上，并对产品底座进行外形定位；将产品透镜(即透明工件13)夹持于固定上模6之上，并对产品透镜进行外形定位，以使产品透镜位于产品底座的上方且与该产品底座对准。
其次，触发启动按钮，利用顶升气缸1驱动产品底座(即激光吸收工件14)移动至预设的焊接点位置处，以使得产品透镜(即透明工件13)与产品底座(即激光吸收工件14)贴合。
之后，利用激光源11发射激光束经导光管62处理并透过产品透镜(即透明工件13)汇聚至产品底座(即激光吸收工件14)的焊接区域进行快速加热，以使得焊接区中物件呈现熔融状态；同时，利用焊接气缸3驱动运动下模5对产品底座(即激光吸收工件14)和产品透镜(即透明工件13)进行压合，进而实现产品透镜(即透明工件13)与产品底座(即激光吸收工件14)之间的焊接。
需要注意的是，上述的激光同步焊接装置及激光同步焊接工艺之间相互支撑，故本领域技术人员应该可知，其相互之间相同或近似的技术特征均可以借鉴通用。
综上所述，本发明的上述实施例中的激光同步焊接工艺及装置，通过利用运动下模和固定上模使得产品底座与产品透镜贴合后，利用诸如聚碳酸酯或玻璃等廉价材质制备的导光管，将激光源发射的激光束处理后形成焊接光斑透过产品透镜照射至产品底座的焊接区域中，进而对焊接区域进行快速、均匀加热；同时，利用焊接气缸对产品底座及产品透镜进行压合，使得产品底座及产品透镜在熔融状态下压合焊接在一起，且焊接时在不产生粉末等缺陷的同时还能使得焊接所产生的废边尺寸小于0.4mm(如废边的高和宽均小于0.4mm)，即能够有效的提高焊接产品的性能。
对于本领域的技术人员而言，阅读上述说明后，各种变化和修正无疑将显而易见。因此，所附的权利要求书应看作是涵盖本发明的真实意图和范围的全部变化和修正。在权利要求书范围内任何和所有等价的范围与内容，都应认为仍属本发明的意图和范围内。

Claims (12)

1.一种激光同步焊接装置，其特征在于，应用于对被焊接物进行同步焊接的工艺中，所述被焊接物包括产品底座和产品透镜，所述装置包括：
顶升气缸；
第一承载板，固定设置于所述顶升气缸之上；
第二承载板，通过焊接气缸设置于所述第一承载板之上；
运动下模，固定设置于所述第二承载板之上，以用于夹持所述产品底座；
固定上模，对应所述运动下模设置于所述运动下模的上方，以用于夹持所述产品透镜；以及
所述固定上模之上设置有激光源和导光管，且所述导光管位于所述激光源与所述产品透镜之间；并且
所述顶升气缸通过所述第一承载板和所述第二承载板驱动所述产品底座移动至焊接点位置处，以使所述产品透镜贴合至所述产品底座之上；所述导光管对所述激光源发射的激光束进行整形并透过所述产品透镜汇聚至所述产品底座的焊接区域进行加热，同时所述焊接气缸通过所述第二承载板驱动所述运动下模对所述产品底座和所述产品透镜进行压合。
2.如权利要求1所述的激光同步焊接装置，其特征在于，所述运动下模上固定设置有产品胎具，且所述产品底座固定设置于所述产品胎具上。
3.如权利要求1所述的激光同步焊接装置，其特征在于，所述导光管包括导光管本体和导光管固定块，所述导光管固定块固定于所述固定上模之上；以及
所述激光源发射的激光束经所述导光管本体处理后至所述产品底座的焊接区域进行加热。
4.如权利要求3所述的激光同步焊接装置，其特征在于，所述固定上模上设置有若干固定孔；以及
所述导光管本体通过所述若干固定孔固定于所述固定上模上，以形成与所述被焊接物上的所述焊接区域匹配的结构形状。
5.如权利要求3所述的激光同步焊接装置，其特征在于，所述导光管本体为管状结构；以及
所述激光源发射的激光束经所述导光管本体处理后分布均匀的条状焊接光斑，所述焊接光斑照射至所述被焊接物的焊接区域进行加热。
6.如权利要求3所述的激光同步焊接装置，其特征在于，所述导光管本体的材质为透明材质。
7.一种激光同步焊接工艺，其特征在于，应用于对包括产品底座和产品透镜的焊接物进行焊接，所述工艺包括：
将所述产品底座固定于设置在运动下模上的产品胎具之上，并继续外形定位；
将所述产品透镜夹持于固定上模上，以使所述产品透镜位于所述产品底座的上方；
利用顶升气缸驱动所述产品底座移动至焊接点位置处，使所述产品透镜与所述产品底座贴合；
激光源发射激光束经处理后透过所述产品透镜汇聚至所述产品底座的焊接区域进行加热；同时，利用焊接气缸驱动所述运动下模对所述产品底座和所述产品透镜进行压合。
8.如权利要求7所述的激光同步焊接工艺，其特征在于，所述导光管包括导光管本体和导光管固定块，所述导光管固定块固定于所述固定上模之上；以及
所述激光源发射的激光束经所述导光管本体处理后至所述产品底座的焊接区域进行加热。
9.如权利要求8所述的激光同步焊接工艺，其特征在于，所述固定上模上设置有若干固定孔；以及
所述导光管本体通过所述若干固定孔固定设置于所述固定上模上，以形成与所述产品底座上的所述焊接区域匹配的结构形状。
10.如权利要求8所述的激光同步焊接工艺，其特征在于，所述导光管本体为管状结构；以及
所述激光源发射的激光束经所述导光管处理后照射至所述产品底座的焊接区域进行加热。
11.如权利要求8所述的激光同步焊接工艺，其特征在于，所述导光管本体的材质为透明材质。
12.如权利要求8所述的激光同步焊接工艺，其特征在于，采用所述激光同步焊接工艺对所述被焊物进行焊接工艺时，不产生粉末，且所产生的废边的尺寸：
0＜H＜0.4mm；
0＜w＜0.4mm；
所述H为所述废边的高度，所述w为所述废边的宽度。
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JP2016057256A JP6105781B2 (ja) 2015-07-17 2016-03-22 レーザーシンクロ溶接プロセスと装置

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