CN105263695B - 包括振动解耦配对工具的超声波焊接设备 - Google Patents

包括振动解耦配对工具的超声波焊接设备 Download PDF

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CN105263695B
CN105263695B CN201480003856.2A CN201480003856A CN105263695B CN 105263695 B CN105263695 B CN 105263695B CN 201480003856 A CN201480003856 A CN 201480003856A CN 105263695 B CN105263695 B CN 105263695B
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welding electrode
ultrasonic
welding
instrument
pairing
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CN105263695A (zh
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T·海尔曼
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Herrmann Ultraschalltechnik GmbH and Co KG
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
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    • B06B1/00—Methods or apparatus for generating mechanical vibrations of infrasonic, sonic, or ultrasonic frequency
    • B06B1/02—Methods or apparatus for generating mechanical vibrations of infrasonic, sonic, or ultrasonic frequency making use of electrical energy
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    • B06—GENERATING OR TRANSMITTING MECHANICAL VIBRATIONS IN GENERAL
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    • B29C65/085—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil using a rotary sonotrode
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明涉及一种超声波焊接设备(1),用于借助以振动解耦的方式安装的焊极(2)以及配对工具(8)来超声波加工材料，该焊极包括具有圆柱筒形状的封接面，其中，转换器可选地通过第一振幅转换单元连接到焊极(2)，并且焊极(2)和第一转换器设计成使得可以以具有超声波频率fS的固有振动将焊极(2)设置成振动。

Description

包括振动解耦配对工具的超声波焊接设备
本发明涉及一种超声波焊接设备，用于借助焊极以及配对工具来超声波加工材料，该焊极以振动解耦的关系安装并具有呈圆柱面形状的封接面，其中，第一转换器可选地通过第一振幅转换部分连接到焊极，并且焊极和第一转换器设计成使得能以频率fS的固有振动致使焊极振动。
超声波加工是连结塑料材料的方法。超声波是大于可听极限的机械振动。频率范围始于大约20kHz并达到1GHz的频率。此类超声波频率通常借助压电声音变换器(转换器)由电能产生。机械振动能量可选地通过振幅转换部分(变幅器)经由连接到转换器的焊极而施加到待加工的工件或材料。旨在与待加工的材料接触的焊极的表面也称为封接面。
超声波振动单元因此代表一种这样的结构，即，该结构在工作时振动并包括转换器，可选地包括振幅转换部分和焊极。
为了有效地借助超声波振动单元发射超声波振动，必须使超声波振动单元达到共振状态。根据超声波振动单元的结构，其具有多个固有频率。仅当转换器产生超声波振动单元的固有频率时发生超声波单元的共振。因此，转换器和超声波振动单元必须彼此匹配。
严格来说，共振频率与固有频率有点不同，因为任何真实系统是有阻尼的。然而在下文中—这也是在文献中常有的情况——术语“共振频率”和“固有频率”同义地使用。
超声波振动单元的最重要固有频率通常是这样的固有频率，即在该固有频率时，具有波节和波腹的驻纵向振动在超声波振动单元中产生。在该情况下，相应波腹形成在焊极的各端部。
产生相应超声波激发频率的转换器连接到各端部之一。可能地，变幅器或振幅转换器连接在转换器和焊极之间，其改变超声波振动的振幅而不是频率。焊极的固有频率以及因此纵向振动的振动节点的位置不由于提供变幅器而受影响。
在借助超声波加工材料的过程中，待加工的材料通常定位于焊极和配对工具(其不属于振动结构)之间，并且该配对工具有时也被称为砧。然后与待加工的材料接触的焊极将超声波能量传递到待加工的材料，待加工的材料由此例如被焊接或切断。通过将超声波振动转换成摩擦能量而产生使材料网塑化所需的热量。因此借助界面和分子摩擦而产生使塑料材料熔融的热量。
在大部分焊极中，纵向超声波振动借助封接面来进行能量传递。
然而，也有类似于这里描述的具有封接面的焊极，该封接面基本上呈圆柱面的形状，该焊极使用横向于超声波振动的纵向传播方向而产生的径向超声波振动来进行能量转移。在超声波加工操作过程中，这些焊极通常绕它们的纵向轴线旋转使得封接面在待加工的材料上滚动。这些焊极允许连续加工。
旨在与待加工的材料接触的配对工具的表面通常也称为封接面。
尤其是当加工较厚材料时，例如当封接像例如牛奶纸盒的折叠纸盒包装的山形缝时，连续加工过程中的连续超声波焊接设备的能量(即当使用具有呈圆柱面形状的封接面的焊极时)不再足以可靠地焊接山形缝。
因此必须使用间断操作的焊极，即采用循环的关系，由此加工时间显著更长。
WO 2008/037256示出了一种具有封接面的超声波焊接装置，该封接面呈圆柱形表面的形状。另外，提出了使用一种用于超声波处理的第二焊极。在FR 2 082 090中描述了一种相应的焊极。
将所述技术现状作为基本出发点，因此，本发明的目的是提供一种在本说明书的开头部分所述的类型的超声波焊接设备，借助于该超声波焊接设备，能以连续操作模式用低水平的能量加工甚至更厚的材料。
根据本发明，该目的通过一种根据权利要求1所述的超声波焊接装置而实现。
正如在焊极的情形中，因此提供的是，使配对工具振动，而该振动的大部分没有传递到保持器。
这意味着保持器接合焊极或配对工具所在的点必须调谐成具有超声波频率fG的固有振动。当使配对工具或焊极振动时，即，使配对工具或焊极处于共振状态时，驻波形成在配对工具或焊极内，具有振动最大值和振动最小值。仅当保持器在有振动最小值所在的区域中接合焊极或配对工具时振动解耦安装布置发生。
配对工具应设计成使得在超声波频率fG下在封接面处具有振动最大值。
如果现在，借助焊极使超声波振动作用于位于焊极与配置工具之间的材料上，则也可使配对工具振动，此致使配对工具也加工材料，由此提高了焊接效率。
根据本发明，配对工具也由超声固有振动激发，使得材料既通过焊极又通过配对工具加工。基本上，此时配对工具也代表焊极。
根据本发明，意为固有频率fG不等于频率fS并且不是其整数倍。具体地说，已经发现，优选地以及特别优选地
例如，焊极可在30kHz的频率下激发而配对工具在35kHz的频率下激发。30kHz振动离配对工具的35kHz频率足够远，使得焊极与配对工具之间几乎没有能量转移。
超声波加工操作通过不同振动频率显著地改进了。
特别优选地，超声波焊接设备具有用于使焊极旋转的驱动器，焊极具有基本上旋转对称的构型。
以相同的方式，可提供用于配对工具旋转的驱动器，其中，配对工具优选地具有基本上旋转对称的构型并具有呈圆柱面的形状的封接面。在该情况下，配对工具和焊极最好地以相反的关系旋转，使得材料在焊极与配对工具之间的超声波加工过程中移动穿过处于一边的焊极与处于另一边的配对工具之间。
焊极的封接面和/或配对工具的封接面可结构化，其中术语“结构化”用于表示在封接面上或在封接面内的任何类型的凸起或凹陷。
在另一优选实施例中，焊极与配对工具之间的间距可调节。特别优选地，提供有邻接件，该邻接件布置成使得焊极与配对工具之间的最小间距保持。
本发明的另外优点、特征将从优选实施例的以下描述中显现出来。在附图中：
图1示出了优选实施例的第一立体图；
图2示出图1的实施例的第二立体图；
图3示出图1的实施例的平面图；以及
图4示出了图1的实施例的侧视图。
图1示出了根据本发明的超声波焊接设备。超声波焊接设备1具有振动解耦焊极2，焊极2具有呈圆柱面的形状的封接面。焊极2通过振幅转换部分连接到转换器。转换器和振幅转换部分设置在壳体3内。可借助转换器使焊极2处于超声波振动状态。另外提供了驱动器4，借助驱动器4，焊极2可绕其纵向轴线旋转。焊极2或其保持器固定到滑架5，滑架5又可借助电动机7相对于支架6移动以调节焊极2相对于配对工具8的间距。
焊极和配对工具之间的间隙宽度可借助电动机调节。这也允许间隙宽度在加工操作过程中调节。因此，例如，间隙大小可被测量并调节到预定目标值。作为其替代，可测量焊极在配对工具上或在沿该配对工具被引导的待加工材料上所借助的力并将该力调节到预定值。对于很多使用的情况，也能测量超声波振动单元的电功率输入并将该电功率输入调节到预定值。在该方面，控制参数是焊极的位置，该位置可借助电动机改变。
配对工具8也通过振幅转换部分连接到转换器，并且转换器和振幅转换部分设置在壳体9中。其结果是也可将超声波振动作用在配对工具8上。配对工具8也具有呈圆柱面的形状的封接面并也可借助驱动器10绕其纵向轴线旋转。
应当注意，焊极和配对工具的封接面在本实施例中具有不同宽度。
图2示出第二立体图。这里，也可以看到，配对工具8通过其保持器安装到机座11。但是，这里，配对工具8的安装也是振动解耦的，使得也能够通过超声波振动作用在配对工具上，同时大部分振动能量没有传递到机架11。
图3和图4示出了图1的实施例的另两个视图。待加工的材料移动穿过焊极2与配对工具8之间并随着其移动而被加工。具体地说，所述实施例尤其适于山形缝的超声波加工。
附图标记列表
1 超声波焊接设备
2 焊极
3,9 壳体
4,10 驱动器
5 滑架
6 支架
7 电动机
8 配对工具
11 机架

Claims (9)

1.一种超声波焊接设备(1)，用于借助焊极(2)以及配对工具(8)来超声波加工材料，所述焊极(2)以振动解耦的关系安装并具有呈圆柱面形状的封接面，其中，第一转换器连接到所述焊极(2)，并且所述焊极(2)和所述第一转换器设计成使得能以具有超声波频率fS的固有振动致使所述焊极(2)振动，其中，所述配对工具(8)具有超声波频率fG的固有振动并且以振动解耦的关系安装使得所述配对工具(8)能由所述超声波频率fG激发，第二转换器连接到所述配对工具(8)，并且所述配对工具(8)和所述第二转换器设计成使得能以具有所述频率fG的固有振动致使所述配对工具(8)振动，其特征在于，所述超声波频率fG不等于所述频率fS并且不是所述频率fS的整数倍。
2.如权利要求1所述的超声波焊接设备(1)，其特征在于，设置有用于使所述焊极(2)旋转的驱动器(4、10)，其中所述焊极(2)具有基本上旋转对称的构型。
3.如权利要求1所述的超声波焊接设备(1)，其特征在于，设置有用于使所述配对工具(8)旋转的驱动器(4、10)，其中，所述配对工具(8)具有基本上旋转对称的构型并具有呈圆柱面的形状的封接面。
4.如权利要求3所述的超声波焊接设备(1)，其特征在于，所述焊极(2)的所述封接面和/或所述配对工具(8)的所述封接面是结构化的。
5.如权利要求1所述的超声波焊接设备(1)，其特征在于：所述焊极(2)与所述配对工具(8)之间的间距能调节。
6.如权利要求1至5中的任何一项所述的超声波焊接设备(1)，其特征在于：
7.如权利要求6所述的超声波焊接设备(1)，其特征在于：
8.如权利要求1所述的超声波焊接设备(1)，其特征在于：所述第一转换器通过第一振幅转换部分连接到所述焊极(2)，所述第二转换器通过第二振幅转换部分连接到所述配对工具(8)。
9.如权利要求5所述的超声波焊接设备(1)，其特征在于：设置有邻接件，所述邻接件布置成使得所述焊极(2)与所述配对工具(8)之间的最小间距被保持。
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