CN105014213A - 电阻点焊方法 - Google Patents

电阻点焊方法 Download PDF

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Publication number
CN105014213A
CN105014213A CN201510201442.7A CN201510201442A CN105014213A CN 105014213 A CN105014213 A CN 105014213A CN 201510201442 A CN201510201442 A CN 201510201442A CN 105014213 A CN105014213 A CN 105014213A
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China
Prior art keywords
conductive coating
conductive
polymer
metal works
resistance spot
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CN201510201442.7A
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CN105014213B (zh
Inventor
G.肖
王培中
J.F.阿林兹
J.C.西默
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GM Global Technology Operations LLC
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GM Global Technology Operations LLC
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/16—Resistance welding; Severing by resistance heating taking account of the properties of the material to be welded
    • B23K11/163—Welding of coated materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/002—Resistance welding; Severing by resistance heating specially adapted for particular articles or work
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/10—Spot welding; Stitch welding
    • B23K11/11—Spot welding
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    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/16—Resistance welding; Severing by resistance heating taking account of the properties of the material to be welded
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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"
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    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
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    • B29C66/74—Joining plastics material to non-plastics material
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    • 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
    • B29C66/83221—Joining or pressing tools reciprocating along one axis cooperating reciprocating tools, each tool reciprocating along one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/912—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux
    • B29C66/9131—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the heat or the thermal flux, i.e. the heat flux
    • B29C66/91311—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the heat or the thermal flux, i.e. the heat flux by measuring the heat generated by Joule heating or induction heating
    • B29C66/91315—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the heat or the thermal flux, i.e. the heat flux by measuring the heat generated by Joule heating or induction heating by measuring the current intensity
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    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/16—Composite materials, e.g. fibre reinforced
    • B23K2103/166—Multilayered materials
    • B23K2103/172—Multilayered materials wherein at least one of the layers is non-metallic
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B23K2103/00—Materials to be soldered, welded or cut
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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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    • B29C66/70—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
    • 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
    • B29C66/74—Joining plastics material to non-plastics material
    • B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
    • B29C66/7422—Aluminium or alloys of aluminium
    • 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
    • B29C66/74—Joining plastics material to non-plastics material
    • B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
    • B29C66/7428—Transition metals or their alloys
    • 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
    • B29C66/74—Joining plastics material to non-plastics material
    • B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
    • B29C66/7428—Transition metals or their alloys
    • B29C66/74283—Iron or alloys of iron, e.g. steel
    • 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
    • B29C66/94—Measuring or controlling the joining process by measuring or controlling the time
    • B29C66/942—Measuring or controlling the joining process by measuring or controlling the time by measuring the time

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  • Engineering & Computer Science (AREA)
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  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

一种电阻点焊方法可用于将聚合物和金属工件连结在一起且包括下列的步骤：(a)将导电涂层置于聚合物工件和金属工件置于，其中金属工件具有面对聚合物工件的带纹理表面；(b)用焊接电极组件的第一和第二导电销穿入聚合物工件；(c)将电能施加到第一和第二导电销，从而电流流过第一导电销、导电涂层和第二导电销，以便至少部分地熔化聚合物工件和导电涂层，由此形成焊接熔池；和将焊接熔池冷却以便形成固态焊核，以便建立固态焊核和带纹理表面之间的机械界面锁合。

Description

电阻点焊方法
技术领域
本发明涉及电阻点焊方法。
背景技术
焊接是用于将两个或更多工件(例如金属基板)连结的工艺。通常，焊接可以包括对至少两个工件加热且加压，以便将工件联合。多年来已经开发了许多焊接工艺。
发明内容
电阻点焊是一类焊接工艺，其中电流经过两个电极和工件，以在工件中产生局部加热。形成工件的材料熔化且在两个工件之间的界面处结合，由此形成焊接熔池。焊接熔池随后冷却以形成焊核。为了提高生产量，有用的是使得完成电阻点焊过程所花费的时间最小化。为了减轻结构重量，有用的是使用电阻点焊将不同材料制造的工件连结。为此，本发明公开一种已经开发出来的电阻点焊方法。
本发明公开的电阻点焊方法可用于将聚合物工件和金属工件连结在一起。在一实施例中，电阻点焊方法包括下列的步骤：(a)将导电涂层施于聚合物工件和金属工件之间，其中金属工件具有面对聚合物工件的带纹理表面；(b)用焊接电极组件的第一和第二导电销穿入(pierce)聚合物工件；(c)将电能施加到第一和第二导电销，从而电流流过第一导电销、导电涂层和第二导电销，以便至少部分地熔化聚合物工件和导电涂层，由此形成焊接熔池(一些加热源自于对金属工件的焦耳加热)；和(d)将焊接熔池冷却以便形成固态焊核，以便建立固态焊核和带纹理表面之间的机械界面锁合(mechanicalinterface lock)，其中该机械界面锁合将聚合物工件互连到金属工件。方法另外包括在将导电涂层置于聚合物工件和金属工件之间之后对聚合物工件和金属工件施加夹持力，以便将聚合物工件压抵金属工件。
根据本发明的一个方面，提出一种电阻点焊方法，包括：
对聚合物工件和金属工件施加夹持力，以便将聚合物工件压抵金属工件，其中金属工件包括面对聚合物工件的带纹理表面，且导电涂层设置在带纹理表面上；
用焊接电极组件的第一和第二导电销穿入聚合物工件；
将电能施加到第一和第二导电销，使得电流流过第一导电销、导电涂层和第二导电销，以便至少部分地熔化聚合物工件和导电涂层，由此形成焊接熔池；和
将焊接熔池冷却以便形成固态焊核，以便建立固态焊核和带纹理表面之间的机械界面锁合，其中该机械界面锁合将聚合物工件互连到金属工件。
优选地，其中带纹理表面具有0.001到2000微米范围内的算术平均粗糙度。
优选地，其中将夹持力施加到聚合物和金属工件包括让焊接电极组件朝向金属工件前进。
优选地，方法进一步包括让第一和第二导电销前进通过聚合物工件直到第一和第二导电销接触设置在聚合物和金属工件之间的导电涂层。
优选地，方法进一步包括在形成焊接熔池之后使第一和第二导电销从聚合物工件退出。
优选地，其中通过自然对流进行冷却。
优选地，其中导电涂层置于聚合物和金属工件之间。
优选地，方法进一步包括将导电涂层置于带纹理表面的、限定工件腔室的部分上，使得导电涂层至少部分地设置在工件腔室中。
优选地，其中聚合物工件具有约270摄氏度的熔点，金属工件具有大于270摄氏度的熔点，且将电能施加到第一和第二导电销包括向导电涂层供应足够的电流达足够量的时间，以便以大于270摄氏度的温度加热聚合物工件和导电涂层，以便形成焊接熔池。
优选地，其中将电能施加到第一和第二导电销包括供应足够的电流到导电涂层达足够量的时间，以便完全熔化导电涂层。
在下文结合附图进行的对实施本发明的较佳模式做出的详尽描述中能容易地理解上述的本发明的特征和优点以及其他的特征和优点。
附图说明
图1是焊接系统的示意性正视截面图；
图2是在聚合物工件、金属工件和在聚合物和金属工件之间的导电涂层的示意性正视截面图；
图3是图2所示的聚合物工件、金属工件、导电涂层的示意性正视截面图，且焊接电极组件将夹持力施加到聚合物和金属工件；
图4是图3所示的聚合物工件、金属工件、导电涂层和焊接电极组件的示意性正视截面图，其中焊接电极组件正对导电涂层施加电能；
图5是图4所示的聚合物工件、金属工件、导电涂层和焊接电极组件的示意性正视截面图，其中焊接电极组件从聚合物工件退出且固态焊核连结金属和聚合物工件；和
图6是焊接接头的示意性正视截面图。
具体实施方式
参见附图，其中相同的附图标记指示相同的部件，图1示意性地示出了用于连结不同材料制造的两个或更多工件的电阻点焊系统100。在所示实施例中，焊接系统100可用于连结聚合物工件10和金属工件20(图3)。聚合物工件10(图3)完全或部分地用合适的聚合物复合材料制造，例如纤维强化聚合物。作为非限制性的例子，合适的聚合物复合材料包括热朔性复合材料，其具有用聚甲基丙烯酸甲酯、聚苯并咪唑、聚乙烯、聚丙烯、聚氯乙烯、聚四氟乙烯等制造的基质。聚合物工件10(图3)还可完全或部分地用碳纤维强化的尼龙化合物制造。形成聚合物工件10的聚合物复合材料具有120摄氏度到600摄氏度的熔点。例如，形成聚合物工件10的聚合物复合材料可以具有约270摄氏度的熔点。作为非限制性的例子，金属工件20完全或部分地用含铁的金属(例如钢和不锈钢)或用不含铁的金属(例如铝、钛和镁)制造。
继续参考图1，焊接系统100包括电连接到电源104的电阻点焊电极组件102，电源例如是直流(DC)电源。焊接电极组件102和电源104是电路106的一部分。电源104包括正端子108和负端子110，且配置为向焊接电极组件102供应电能。换句话说，电源104可供应电流到焊接电极组件102。
除了电源104之外，电路106包括串联地电连接到电源104到电开关112。电开关112可在接通(ON)状态(或位置)和断开(OFF)状态(或位置)之间变换。在接通状态下，电开关112允许电流流过电路106。如此，在电开关112处于接通状态时，电流可从电源104流动到焊接电极组件102。相反地，在电开关处于断开状态时，电开关112中断从电源104而来的电流流动。由此，在断开状态下，电开关112中断电路106，且因此电流不能从电源104流动到焊接电极组件102。
焊接系统100另外包括串联地电连接到电源104的安培计114。安培计114可测量电路106中的电流。应理解，安培计114可以是动圈式安培计、电动式安培计、动铁式安培计、热线式安培计、数字安培计、积算安培计或适于测量电路106中电流的任何其他类型的安培计。
焊接系统100进一步包括用于测量时间间隔的计时器116。在所示实施例中，计时器116并联地电连接到电源104。计时器116可用于测量和监测电源104将电流供应到焊接电极组件102的时间。
参见图1和3，焊接电极组件102电连接到电源104且包括壳体118。壳体118限定第一和第二开口120、122(图1)，所述开口彼此间隔开。作为非限制性的例子，第一和第二开口120、122可以是一个或多个孔或洞，且基本上平行于彼此。壳体118可以限定壳体腔室119(图1)。
焊接电极组件102进一步包括从壳体118突出的第一和第二导电销124、126。第一和第二导电销124、126可以分别称为第一和第二电极，且每一个至少部分地设置在壳体118中。在所示实施例中，第一导电销124部分地设置在第一开口120中，且第二导电销126部分地设置在第二开口122中。换句话说，第一开口120部分地接收第一导电销124，且第二开口122部分地接收第二导电销126。第一和第二开口120、122与壳体腔室119连通，且壳体腔室119部分地接收第一和第二导电销124、126。第一和第二开口120、122彼此并排且平行布置。因而，第一和第二导电销124、126也彼此并排且平行布置。
第一和第二导电销124、126完全或部分地用导电材料制造，例如金属，其具有的硬度按Rockwell C度量为50HRC到70HRC。作为非限制性的例子，形成第一和第二导电销124、126的材料的硬度按Rockwell C度量为约65HRC。有用的是，第一和第二导电销124、126至少部分地用具有如上所述硬度和硬度范围的导电材料制造，从而第一和第二导电销124、126可穿入聚合物工件10(图3)。聚合物工件10具有按Rockwell C度量的10HRC到50HRC的硬度，以便允许第一和第二导电销124、126(具有如上所述的硬度)穿入聚合物工件10。作为非限制性的例子，第一和第二导电销124、126可以完全或部分地用钢制造。例如，第一和第二导电销124、126每一个可以完全或部分地用高速钢T1/高速钢M2或H-13工具钢制造。进一步地，第一和第二导电销124、126可以完全或部分地用碳化钨、铜合金、钴合金钢、基于钨或钼的合金制造。
为了有助于穿入聚合物工件10，第一和第二导电销124、126每一个分别包括锥形的或尖的末端125、127。锥形末端125、127也可以限定沟槽，以有助于穿入聚合物工件10。
第二导电销126与第一导电销124电绝缘。如此，电流不能从第一导电销124直接流动到第二导电销126。为了让第一和第二导电销124、126彼此电绝缘，焊接电极组件102包括第一电绝缘覆盖件128和第二电绝缘覆盖件130。第一和第二电绝缘覆盖128、130完全或部分地用电绝缘材料制造，例如聚合物。第一电绝缘覆盖件128部分地设置在第一开口120中且至少部分地围绕第一导电销124。因而，第一开口120部分地接收第一电绝缘覆盖件128和第一导电销124。第二电绝缘覆盖件130部分地设置在第二开口122中且至少部分地围绕第二导电销126。因此，第二开口122部分地接收第二电绝缘覆盖件130和第二导电销126。替换地或除了第一和第二电绝缘覆盖128、130以外，焊接电极组件102可以包括电绝缘体129(图3)，以便将第一导电销124与第二导电销126电分离。
焊接电极组件102包括将第一导电销124电连接到电源104的正端子108的第一导电连接件132。电开关112串联地电连接在电源104的正端子108和第一导电销124之间。进一步地，焊接电极组件102包括将第二导电销126电连接到电源104的负端子110的第二导电连接件134。安培计114串联地电连接在电源104的负端子110和第二导电连接件134之间。
图2-5示意性地显示了使用如上所述焊接系统100的电阻点焊方法。首先，在图2中，通过将导电涂层30施于聚合物工件10和金属工件20之间而开始该方法。换句话说，导电涂层30被施于聚合物工件10和金属工件20之间的界面处(即焊接界面)。在焊接界面处不需要放置其他加热元件。导电涂层30完全或部分地导电且导热的材料制造。作为非限制性的例子，导电涂层30可以是碳黑或热朔性材料。例如，导电涂层30可以是石墨导电涂层、总地碳导电涂层(total ground carbon conductive coating)或镀银的铜导电涂层。金属工件20可以包括工件腔室24，所述工件腔室配置、成形且大小设置为至少部分地接收导电涂层30。此外，聚合物工件10限定聚合物接合表面12，且第二工件20限定带纹理表面22。
参考图6，带纹理表面22具有0.001微米到2000微米的范围上的算术平均粗糙度Ra。例如，带纹理表面22可以具有约2微米的算术平均粗糙度Ra。如上所述的算术平均粗糙度和范围有助于建立聚合物工件10和金属工件20之间的机械界面锁合。为了让带纹理表面22带有纹理，金属工件20可经历任何合适的表面粗加工处理。表面粗加工处理可以是化学处理，例如石版印刷术，或机械处理，例如研磨、抛光、喷砂、激光处理或3-D打印。带纹理表面22的一部分22A限定工件腔室24。因此，限定工件腔室24的、带纹理表面22的该部分22A也具有0.001微米到2000微米范围上的算术平均粗糙度Ra，以便有助于建立聚合物工件10和金属工件20之间的机械界面锁合。带纹理表面22的纹理可具有预定的样式，以便增强聚合物工件10和金属工件20之间的机械界面锁合。
再次参考图2-5，在图2示出的步骤中，导电涂层30被首先施于带纹理表面22上。例如，导电涂层30可被完全地或部分地施于限定了工件腔室24的、带纹理表面22的该部分22A上，使得导电涂层30至少部分地接收在工件腔室24中。随后，聚合物工件10被置于导电涂层30和金属工件20的顶部上，使得第一接合表面12面对带纹理表面22。由此，带纹理表面22面对聚合物工件10。层密封剂或粘接剂被施加在金属工件20和聚合物工件10之间，以改善密封且防止侵蚀。随后，方法继续到图3示出的步骤。
图3示出了焊接电极组件102朝向聚合物工件10前进从而第一和第二导电销124、126穿入聚合物工件10的步骤。换句话说，图3示出的步骤实现了用第一和第二导电销124、126穿入聚合物工件10。一旦第一和第二导电销124、126穿入聚合物工件10，则焊接电极组件102沿箭头F1示出的方向(即朝向金属工件20)前进，以便让第一和第二导电销124、126前进通过聚合物工件10。第一和第二导电销124、126同时沿箭头F1示出的方向前进通过聚合物工件10，直到第一和第二导电销124、126接触设置在聚合物和金属工件10、20之间的导电涂层30。焊接电极组件102可以包括支撑构件121(即非导电构件)，其能在第一和第二导电销124、126同时前进通过聚合物工件10时支撑聚合物工件10、导电涂层30和金属工件20。由此，图3示出的步骤实现了让第一和第二导电销124、126前进通过聚合物工件10直到第一和第二导电销124、124接触设置在聚合物工件10和金属工件20之间的导电涂层30。
图3所示的步骤还实现了对聚合物工件10施加压力(通过沿箭头F1和F2示出的方向施加夹持力)，以便将聚合物工件10压抵导电涂层30和金属工件20。换句话说，夹持力施加到聚合物工件10和金属工件20，以便将聚合物工件10压抵金属工件20。为此，焊接电极系统102沿箭头F1示出的方向朝向聚合物工件10和导电涂层30前进，直到壳体118接触聚合物工件10。一旦壳体118接触聚合物工件10，则焊接电极组件102连续沿箭头F1示出的方向连续前进，以便将聚合物工件10压抵导电涂层30和金属工件20。在壳体118沿箭头F1示出的方向运动时，支撑构件121可沿箭头F2示出的方向运动，以便对聚合物工件10和金属工件20施加夹持力。由此，壳体118抵靠聚合物工件10施加压力，以便将聚合物工件10夹持抵靠金属工件20。焊接电极组件102可在聚合物工件10上施加压力，同时，让第一和第二导电销124、126前进通过聚合物工件10。因为焊接电极组件102用于在聚合物工件10和金属工件20上施加压力且在聚合物工件10和金属工件20之间的界面处传导电流，所以焊接电极组件102可以被称为混合焊接电极组件。
虽然在压力施加到聚合物工件10时让第一和第二导电销124、126前进通过聚合物工件10，但是第一和第二导电销124、126不穿入金属工件20。第一和第二导电销124、126仅沿箭头F1方向前进通过聚合物工件10直到第一和第二导电销124、126接触导电涂层30，但在它们接触金属工件20之前。
如图4所示，一旦第一和第二导电销124、126接触导电涂层30，则电能施加到第一和第二导电销124、126，使得电流首先(从电源104)流动到第一导电销124，随后通过导电涂层30，且接下来通过第二导电销126。电源104以足够的电流且以足够的时间将电能供应到导电涂层30(经由第一和第二导电销124、126)，以熔化导电涂层30和聚合物工件10的至少一部分，由此形成焊接熔池W。焊接熔池W包括熔化的聚合物(来自聚合物工件10)和熔化的涂层30。用在涂层30中的填充物(为了获得适当的抵抗力)也会加强焊接部。因为工件20具有比聚合物工件10更高的熔点，所以金属工件20不由于在电流流过导电涂层30和金属工件20时产生的热量而熔化。如上所述，聚合物工件10用具有约270摄氏度的熔点的聚合物复合材料制造。由此，足够高的电流经过导电涂层30达足够量的时间，以便以大于270摄氏度的温度加热聚合物工件10和导电涂层30。所需的电流和时间取决于所选择的电阻率(resistivity)。在这种加热过程中，导电涂层30完全地熔化且围绕导电涂层30的聚合物工件10的仅一些部分熔化以形成焊接熔池W。因为形成金属工件20的金属材料的熔点大于270摄氏度，所以在电流流过导电涂层30时金属工件20不熔化。聚合物工件10和导电涂层30的熔化部分沿金属工件20的带纹理表面22传播(见图6)。
如图5所示，在形成焊接熔池W之后，第一和第二导电销124、126从聚合物工件10取出。为此，焊接电极组件102从聚合物工件10沿箭头R示出的方向(图4)运动离开。焊接熔池W最初是液态且随后冷却，以便形成固态焊核N，其将聚合物工件10和金属工件20连结。换句话说，图5所示的步骤实现了冷却焊接熔池W，直到焊接熔池W固化且形成固态焊核N。冷却可以通过自然的传导实现。即焊接熔池W可以被允许降温。不管冷却的方法如何，一旦焊接熔池W冷却下来，则其形成将聚合物和金属工件10、20连结的固态焊核N。
参考图6，焊接接头J将金属工件20和聚合物工件10连结，且其强度通过固态焊核N与金属工件20的带纹理表面22之间的机械界面锁合而被增强。因为焊接熔池W沿带纹理表面22冷却，所以固态焊核N因此沿带纹理表面22的峰部P和谷部V传播。固态焊核N沿带纹理表面22的峰部P和谷部V的定位建立了聚合物工件10和金属工件20之间的机械界面锁合，且该机械界面锁合阻止或至少妨碍金属工件20相对于聚合物工件10沿多个方向的运动。换句话说，焊接方法包括(通过自然的对流)冷却焊接熔池W，以便形成固态焊核N，以便建立固态焊核N和带纹理表面22之间的机械界面锁合，且该机械界面锁合将聚合物工件10互连到金属工件20。焊接方法由此包括冷却焊接熔池W，以便形成固态焊核N，以便建立固态焊核N和带纹理表面22之间的机械界面锁合，且机械界面锁合将聚合物工件10互连到金属工件20。
尽管已经对执行本发明的较佳模式进行了详尽的描述，但是本领域技术人员可得知在所附的权利要求的范围内的用来实施本发明的许多替换设计和实施例。
相关申请的交叉引用
本申请要求于2014年4月24日递交的美国临时专利申请NO.61/983,655的权益，该申请通过引用全部合并于此。

Claims (10)

1.一种电阻点焊方法，包括：
将导电涂层置于聚合物工件和金属工件之间，其中金属工件具有面对聚合物工件的带纹理表面；
用焊接电极组件的第一和第二导电销穿入聚合物工件；
将电能施加到第一和第二导电销，使得电流流过第一导电销、导电涂层和第二导电销，以便至少部分地熔化聚合物工件和导电涂层，由此形成焊接熔池；和
将焊接熔池冷却以便形成固态焊核，以便建立固态焊核和带纹理表面之间的机械界面锁合，其中该机械界面锁合将聚合物工件互连到金属工件。
2.如权利要求1所述的电阻点焊方法，其中带纹理表面具有0.001到2000微米范围内的算术平均粗糙度。
3.如权利要求1所述的电阻点焊方法，进一步包括将夹持力施加到聚合物和金属工件以便将聚合物工件压抵导电涂层和金属工件。
4.如权利要求3所述的电阻点焊方法，进一步包括让第一和第二导电销前进通过聚合物工件直到第一和第二导电销接触设置在聚合物和金属工件之间的导电涂层。
5.如权利要求1所述的电阻点焊方法，进一步包括在形成焊接熔池之后使第一和第二导电销从聚合物工件退出。
6.如权利要求1所述的电阻点焊方法，其中通过自然对流进行冷却。
7.如权利要求1所述的电阻点焊方法，其中将导电涂层置于聚合物和金属工件之间包括将导电涂层置于带纹理表面上。
8.如权利要求7所述的电阻点焊方法，其中放置导电涂层包括将导电涂层置于带纹理表面的、限定工件腔室的部分上，使得导电涂层至少部分地设置在工件腔室中。
9.如权利要求8所述的电阻点焊方法，其中聚合物工件具有约270摄氏度的熔点，金属工件具有大于270摄氏度的熔点，且将电能施加到第一和第二导电销包括向导电涂层供应足够的电流达足够量的时间，以便以大于270摄氏度的温度加热聚合物工件和导电涂层，以便形成焊接熔池。
10.如权利要求1所述的电阻点焊方法，其中将电能施加到第一和第二导电销包括供应足够的电流到导电涂层达足够量的时间，以便完全熔化导电涂层。
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