CN105689912A - 用于连结部件的系统和方法 - Google Patents

用于连结部件的系统和方法 Download PDF

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Publication number
CN105689912A
CN105689912A CN201510912614.1A CN201510912614A CN105689912A CN 105689912 A CN105689912 A CN 105689912A CN 201510912614 A CN201510912614 A CN 201510912614A CN 105689912 A CN105689912 A CN 105689912A
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CN
China
Prior art keywords
workpiece
groove
forming
degree
weld seam
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN201510912614.1A
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English (en)
Inventor
H-T.范
C-S.王
J.F.阿里内茨
S.M.斯米思
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GM Global Technology Operations LLC
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GM Global Technology Operations LLC
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Filing date
Publication date
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Publication of CN105689912A publication Critical patent/CN105689912A/zh
Pending legal-status Critical Current

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Classifications

    • 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
    • B23K33/00—Specially-profiled edge portions of workpieces for making soldering or welding connections; Filling the seams formed thereby
    • B23K33/004—Filling of continuous seams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/04—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the partial melting of at least one layer
    • 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
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • 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
    • 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
    • B29C65/44—Joining a heated non plastics element to a plastics element
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B29C65/44—Joining a heated non plastics element to a plastics element
    • B29C65/46—Joining a heated non plastics element to a plastics element heated by induction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
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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
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
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    • B29C65/645—Joining a non-plastics element to a plastics element, e.g. by force using friction or ultrasonic vibrations
    • 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
    • B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
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    • B29C66/23—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations
    • B29C66/232—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations said joint lines being multiple and parallel, i.e. the joint being formed by several parallel joint lines
    • 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
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/23—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations
    • B29C66/234—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations said joint lines being in the form of tessellations
    • 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
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/24—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight
    • B29C66/242—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours
    • B29C66/2422—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being circular, oval or elliptical
    • B29C66/24221—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being circular, oval or elliptical being circular
    • 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
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/24—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight
    • B29C66/242—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours
    • B29C66/2424—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being a closed polygonal chain
    • B29C66/24243—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being a closed polygonal chain forming a quadrilateral
    • B29C66/24244—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being a closed polygonal chain forming a quadrilateral forming a rectangle
    • B29C66/24245—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being a closed polygonal chain forming a quadrilateral forming a rectangle forming a square
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/3022—Particular design of joint configurations the area to be joined comprising melt initiators said melt initiators being integral with at least one 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
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
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    • B29C66/3024—Particular design of joint configurations the area to be joined comprising melt initiators said melt initiators being non-integral with the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/3032—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined
    • B29C66/30325—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined making use of cavities belonging to at least one of the parts to be joined
    • 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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    • 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
    • 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
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    • 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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Abstract

本发明提供用于连结部件的系统和方法。本技术公开了用于通过互锁焊缝连结第一工件和第二工件的方法以及由此形成的产品。第一工件具有第一表面和与第一表面相对的第二表面，并且第二工件具有第一表面、形成在第一表面中的凹槽和与第一表面相对的第二表面。系统通过如下来形成：向系统施加能量，从而至少部分地熔化第一工件的材料，并且使得材料流入到凹槽中，并且允许或使得材料冷却，从而形成连接工件的互锁焊接接头。

Description

用于连结部件的系统和方法
技术领域
本技术总体上涉及连结部件。更具体而言，本技术涉及用于将所连结的部件互锁的系统和方法。
背景技术
因为行业努力实现来自工程结构（例如汽车、航空和航海等等）的减重和改进性能，所以连结具有相似或不同材料性质的工件变得日益重要。
连结相似或不同材料的工艺包括机械连结（例如螺栓和铆钉）、融合连结（例如，融合弧焊和激光焊接）、固态连结（例如，摩擦搅拌焊接和超声波焊接）、钎焊和锡焊以及粘合剂粘结等等。
由于材料的不同化学、机械和热性能，使得连结不同材料提出了挑战，这在连结相似材料时是不存在的。当设计不同材料接头时，必须考虑多种因素，例如但不限于每种材料的材料厚度、表面能量、熔化温度的差异、热膨胀/收缩。甚至在将上述因素考虑在内的情况下，例如焊接和锡焊等连结技术所提供的表面结合在例如剥离应力等某些方向性负载下仍然会倾向于失效。
连结不同材料包括如下挑战：例如避免由于热膨胀系数的不同而容易在材料内形成的扭曲和应力。这些不良情况会导致应力腐蚀开裂，这会削弱结合并且会导致接头的过早失效。
连结不同材料的其它方法使用紧固件，例如粘合剂、铆钉和螺栓。然而，这些紧固件导致例如粘合剂的结构崩塌及铆钉和螺栓的电化腐蚀等问题。另外，这些紧固件增加了相当大的重量，这与大多数行业中朝向更轻部件的趋势是相反的。
发明内容
由于上述缺陷，使得存在对于以下系统和方法的需求：无需增加例如粘合剂、铆钉或螺栓等紧固件，就将包含不同材料的工件牢固地连结。所提出的系统和方法将通过根据不使用附加紧固件的独特技术将工件的材料机械地互锁来连结工件。
本技术包括一种系统，利用该系统，通过在工件中的至少一个的接头界面处形成凹槽来实现机械互锁。凹槽构造成接收来自连结工件的熔化材料，用于在熔化材料冷却时形成可靠的接头。
在一些实施例中，被连结的材料的成分是相似的。在这些实施例中，凹槽能够形成在工件中的任一个或两个工件中。在一个实施例中，第一工件构造成熔化并填充第二工件的凹槽。随着第一工件填充第二工件的凹槽，凹槽略微熔化以增加接头处的互锁。
在其它实施例中，被连结的材料的成分不同。在这些实施例中，凹槽应该形成在具有最高熔化温度的材料内。将凹槽形成到具有较高熔化温度的工件中允许具有较低熔化温度的材料熔化并流入到凹槽中。在用于连结具有不同成分的部件的一些实施方式中，例如根据较高熔点的值和来自较低熔点部件的熔融材料的温度，熔融材料能够不使凹槽变形或者仅使凹槽略微变形地流入到凹槽中。虽然在一些情况下使得凹槽变形通过促进如上所述的互锁而会是有益的，但是相比于不使用凹槽的焊接，基本或完全地维持凹槽结构也能够基于凹槽形状、凹槽尺寸和材料而例如促进互锁和更强焊缝的形成。
本技术的许多益处中的另一益处包括：能够形成对于与接头界面相对的至少一个表面的外观具有最小负面影响或不具有负面影响的连结界面。
在一些实施例中，通过使用激光加热来融化待引入到其它工件的凹槽的工件之一的材料，来最小化或完全避免对于与接头界面相对的至少一个表面的外观的负面影响。在其它实施例中，通过使用感应加热来熔化与凹槽相对的工件，从而限制或避免负面影响。
本技术的其它方面在下文中将是部分显然的并且部分指出的。
1.一种用于在第一工件和第二工件之间形成接头表面的方法，包括：
提供所述第一工件的与第一表面相对的第二表面，用于与所述第二工件的第一表面接触，所述第二工件的第一表面与所述第二工件的第二表面相对，所述第二工件的第一表面具有形成在其中的凹槽；
向所述第一工件和所述第二工件中的至少一个施加能量，从而使得所述第一工件的材料熔化，产生熔融材料并且流入到形成在所述第二工件的第一表面中的所述凹槽中；以及
允许或使得所述熔融材料冷却，从而形成将所述第一工件连结到所述第二工件的互锁焊缝。
2.根据方案1所述的方法，其中形成所述系统还包括机械地、电气地或者通过化学蚀刻而将所述凹槽形成到所述第二工件的第一表面中。
3.根据方案1所述的方法，其中所述凹槽相对于所述第二工件的第一表面以90度至0度之间的角度延伸。
4.根据方案1所述的方法，其中:
所述第二工件的第一表面具有形成在其中的多个凹槽；
所述凹槽中的第一凹槽具有在参考系中从所述第二工件的第一表面以0度至90度之间的第一角度延伸的侧面，并且所述凹槽中的第二凹槽具有在所述参考系中从所述第二工件的第一表面以90度至180度之间的第二角度延伸的侧面；以及
在形成所述系统时施加的能量包括将所述第一工件的材料熔化，从而使得熔化的材料流入到在所述第二工件的第一表面中形成的所述凹槽的每个中，从而形成将所述第一工件连结到所述第二工件的互锁焊缝。
5.根据方案1所述的方法，其中:
在施加所述能量之前，所述第一工件包括从与所述第二工件的第一表面中的所述凹槽相对的第二表面延伸的凸起；并且
在形成所述系统时施加能量以将所述第一工件的材料熔化包括将所述凸起的至少一部分熔化，使其流入到所述凹槽中，从而形成将所述第一工件连结到所述第二工件的互锁焊缝。
6.根据方案1所述的方法，其中在形成所述系统时施加能量以将所述第一工件的材料熔化包括以下之一：应用激光来熔化所述第一工件的材料；应用感应来熔化所述第一工件的材料；以及应用超声波振动来熔化所述第一工件的材料。
7.一种系统，包括：
第一工件，包括第一表面和与所述第一表面相对的第二表面；以及
第二工件，包括第一表面，该第一表面与所述第一工件的第二表面通过互锁焊缝连接，并且具有形成在其中的形成所述互锁焊缝的一部分的凹槽；
其中所述系统通过以下来形成：
　　使得所述第一工件的第二表面与所述第二工件的第一表面接触；
　　向所述第一工件和所述第二工件中的至少一个施加能量，从而使得所述第一工件的材料熔化，产生熔融材料并且流入到在所述第二工件的第一表面中形成的所述凹槽中；以及
　　允许或使得所述熔融材料冷却，从而形成将所述第一工件连结到所述第二工件的互锁焊缝。
8.根据方案7所述的系统，其中形成所述系统还包括机械地、电气地或者通过化学蚀刻而将所述凹槽形成到所述第二工件的第一表面中。
9.根据方案7所述的系统，其中所述凹槽相对于所述第二工件的第一表面以90度至0度之间的角度延伸。
10.根据方案7所述的系统，其中:
所述第二工件的第一表面具有形成在其中的多个凹槽；
所述凹槽中的第一凹槽具有在参考系中从所述第二工件的第一表面以0度至90度之间的第一角度延伸的侧面，并且所述凹槽中的第二凹槽具有在所述参考系中从所述第二工件的第一表面以90度至180度之间的第二角度延伸的侧面；并且
在形成所述系统时施加的能量包括将所述第一工件的材料熔化，使得熔化的材料流入到在所述第二工件的第一表面中形成的所述凹槽的每个中，从而形成将所述第一工件连结到所述第二工件的互锁焊缝。
11.根据方案7所述的系统，其中:
所述凹槽具有第一壁和第二壁；
所述第一壁的至少一部分在参考系中从所述第二工件的第一表面以0度至90度之间的第一角度延伸；并且
所述第二壁的至少一部分在所述参考系中从所述第二工件的第一表面以90度至180度之间的第二角度延伸。
12.根据方案7所述的系统，其中:
在施加所述能量之前，所述第一工件包括从与所述第二工件的第一表面中的所述凹槽相对的第二表面延伸的凸起；并且
在形成所述系统时施加能量以将所述第一工件的材料熔化包括将所述凸起的至少一部分熔化，使其流入到所述凹槽中，从而形成将所述第一工件连结到所述第二工件的互锁焊缝。
13.根据方案7所述的系统，其中在形成所述系统时施加能量以将所述第一工件的材料熔化包括以下之一：应用激光来熔化所述第一工件的材料；应用感应来熔化所述第一工件的材料；以及应用超声波振动来熔化所述第一工件的材料。
14.一种系统，包括：
第一工件，包括第一表面和与所述第一表面相对的第二表面；以及
第二工件，包括第一表面，该第一表面与所述第一工件的第二表面通过互锁焊缝连接，并且具有形成在其中的形成所述互锁焊缝的一部分的凹槽；
其中所述系统通过以下来形成：
　　使得所述第一工件的第二表面与所述第二工件的第一表面接触；
　　向所述第一工件和所述第二工件中的至少一个施加能量，从而使得所述第一工件的材料熔化，产生熔融材料，并且使在所述第二工件的第一表面中形成的所述凹槽的壁材料软化从而产生软化材料；以及
　　允许或使得所述第一工件的所述熔融材料流入到所述第二工件的所述凹槽中；以及
　　允许或使得所述第一工件的所述熔融材料和所述第二工件的所述凹槽的所述软化材料冷却，从而形成将所述第一工件连结到所述第二工件的互锁焊缝。
15.根据方案14所述的系统，其中所述壁材料在形成所述系统时通过流入到所述凹槽中的熔融材料而被软化。
16.根据方案14所述的系统，其中所述壁材料中的至少一些在形成所述系统时在所述熔融材料流入所述凹槽中之前软化。
17.根据方案14所述的系统，其中:
所述第二工件的第一表面具有形成在其中的多个凹槽；
所述凹槽中的第一凹槽具有在参考系中从所述第二工件的第一表面以0度至90度之间的第一角度延伸的侧面，并且所述凹槽中的第二凹槽具有在所述参考系中从所述第二工件的第一表面以90度至180度之间的第二角度延伸的侧面；并且
在形成所述系统时允许或使得所述第一工件的所述熔融材料流入到所述第二工件的所述凹槽中包括：允许或使得所述熔融材料流入到在所述第二工件的第一表面中形成的所述凹槽的每个中，从而形成将所述第一工件连结到所述第二工件的互锁焊缝。
18.根据方案14所述的系统，其中所述凹槽具有第一壁和第二壁，所述第一壁的至少一部分在参考系中从所述第二工件的第一表面以0度至90度之间的第一角度延伸，并且所述第二壁的至少一部分在所述参考系中从所述第二工件的第一表面以90度至180度之间的第二角度延伸。
19.根据方案14所述的系统，其中:
在施加所述能量之前，所述第一工件包括从与所述第二工件的第一表面中的所述凹槽相对的第二表面延伸的凸起；并且
在形成所述系统时施加能量以将所述第一工件的材料熔化包括将所述凸起的至少一部分熔化，使其流入到所述凹槽中，从而形成将所述第一工件连结到所述第二工件的互锁焊缝。
20.根据方案14所述的系统，其中在形成所述系统时施加能量以将所述第一工件的材料熔化包括以下之一：应用激光来熔化所述第一工件的材料；应用感应来熔化所述第一工件的材料；以及应用超声波振动来熔化所述第一工件的材料。
附图说明
图1示出了用于在第一工件和第二工件之间产生可靠互锁的示例连结系统的剖视图。
图2示出了使用图1的示例连结系统中的一个的一部分的激光加热连结工艺的剖视图。
图3示出了使用图1的示例连结系统的另一部分的感应加热连结工艺的剖视图。
图4示出了使用图1的示例连结系统的另一部分的超声波加热连结工艺的剖视图。
图5示出了由图1的连结系统形成的示例性图案的俯视图。
具体实施方式
根据需要，在此公开了本发明的具体实施例。所公开的实施例仅是示例，其可以以各种替代形式及其组合来实施。当在本文中使用时，“例如”、“示例性”、“例示的”和相似术语广泛地指代用作例示、样本、模型或样式的实施例。
附图不必是成比例的，并且一些特征可以被放大或缩小，例如以便示出具体部件的细节。在一些情况下，为了避免使本发明模糊，而没有详细地描述公知部件、系统、材料或方法。因此不将这里公开的特定结构和功能细节解释为限制性的，而是仅作为权利要求的基础，并且作为教导本领域技术人员来多样地实施本发明的代表性基础。
I.技术概述–图1
图1示出了包括第一工件110和第二工件120的连结系统100。第一工件110和第二工件120可以具有相似的材料结构。例如，第一工件110和第二工件120二者可以均由聚合物复合材料构成。相反，第一工件110能够由与第二工件120不同的材料制成。例如，第一工件110可以是复合材料，而第二工件120可以是铝合金。
在一些实施例中，工件110、120中的至少一个包括聚合物，例如聚碳酸脂、聚烯烃（例如，聚乙烯和聚丙烯）、聚酰胺（例如尼龙）、聚丙烯酸酯或者丙烯腈-丁二烯-苯乙烯。
在一些实施例中，工件110、120中的至少一个包括复合材料，例如加强热塑性塑料。塑料可以包括上文列出的任意示例性聚合物，并且加强物可以包括粘土、玻璃、碳、颗粒、（短的或长的）纤维、小板和细须形式的聚合物等等中的一种或更多种。
第一工件110包括第一表面112和第二表面114，并且第二工件120包括第一表面122和第二表面124。在一个实施例中，第一工件110定位在第二工件120上方用于连结，在这种情况下，在连结时，第一工件110的第二表面114和第二工件的第一表面122接触。
为了在工件110、120之间产生增强的互锁，而在工件110、120的连结表面（例如，第一工件110的第二表面114或者第二工件120的第一表面122）内形成至少一个凹槽。凹槽在工件110、120内形成腔，并且构造为接收来自连结工件的熔化材料。
在第一工件110和第二工件120由相似材料制成的情况下，凹槽能够形成在任一工件内。工件110、120的相似性可以关于以下特性：例如但不限于工件110、120是否由相同的材料成分构成、是否具有相似的热膨胀系数或者是否具有相似的熔点。
在工件110、120包括相似材料的实施例中，第一工件110构造成熔化并填充第二工件120的凹槽。随着第一工件110的材料的温度升高（由于例如用于连结工件110、120的超声波能量和/或压缩力），第一工件110的材料熔化并且开始填充第二工件120的凹槽。
随着第二工件120的凹槽开始使用从第一工件110流出的熔化（例如熔融的）材料填充，由腔限定的凹槽的壁可能略微软化（例如，熔化）。在来自第一工件的熔融材料流入第二工件120中的凹槽中之前，至少一些壁材料被软化。凹槽壁的略微软化可以提供接头界面处的附加互锁，这是因为这两个单独的表面（例如，第一工件110的熔化表面和凹槽的软化表面）比如果凹槽壁没有熔化时的表面将具有更大的相互作用，从而冷却以形成高度连结的界面。
在一些实施例的实施方式中，第一工件110和第二工件120的一些材料在凹槽中混和，以形成第一工件110的第二表面114和第二工件120的第一表面122的增强互锁。在实施方式中，第一工件110的第二表面114和第二工件120的第一表面122连结，以在凹槽中形成不存在可分辨表面的连接，如果在该区域中材料没有熔化在一起，则会存在可分辨表面。
当第一工件110和第二工件120包括不同的材料时，凹槽应该形成在具有最高熔化温度的材料内。例如，当将能够具有600至大约1200℃的熔化温度的金属工件与能够具有大约100至大约300℃之间的熔化温度的热塑性工件结合时，凹槽应该形成在金属工件内。热塑性工件将在比金属工件低的温度下熔化，从而使得热塑性材料流入到在金属工件内形成的凹槽中。
能够使用机械方法（例如锯切和冲压）、电气方法（例如激光和放电加工（EDM））、化学方法（例如蚀刻）等等来产生凹槽。在图1的示例性实施例中，第一工件110具有比第二工件120低的熔化温度。因此，凹槽形成在第二工件120内。相反，如果第二工件120具有比第一工件110低的熔化温度，则凹槽将形成在第一工件内。
可以使用激光、EDM或者其他切口加工方法将键形凹槽130插入到第二工件120中。键形凹槽130提供了第一工件110与第二工件120的附加互锁。随着第一工件110在结合期间被加热，材料开始熔化并且填充键形凹槽。
如图1中的第一键形凹槽130所示，在接头设计成承受沿特定方向的负载强度时，单侧键形凹槽是有益的。例如，在将键形凹槽130沿预定方向插入到第一工件110中的情况下，可以使用单侧键形凹槽。
键形凹槽130具有足以从第一工件110接收材料的长度132。键形凹槽130的长度132可以是在大约10微米（μm）至大约1000毫米（mm）之间。
键形凹槽130相对于工件的连结表面（例如第二工件120的第一表面122）以角度134形成。角度134将来自第一工件110的熔化材料与由键形凹槽130生成的空隙的互锁增强。角度134可以提供附加结构来强化接头而防止断裂（例如剥离断裂）。
角度134能够从第一表面122具有0至90度之间的范围。在一些实施例中，角度134可以在大约30至60度之间。在一些实施例中，角度134可以是大约45度。
在一些实施例中，两个或更多个键形凹槽130定位成重叠，从而生成用于增加接触表面积的开口，用于接收熔化时来自第一工件110的材料（如图1中的第二和第三键形凹槽130所示）。在结合期间增加接触表面积能够提高连结之后的结合强度。
在多键形凹槽实施例中，每个键形凹槽130均能够相对于第一表面122定位（例如角度134）。在多键形凹槽实施例中，第一键形凹槽130能够具有从第二工件120的第一表面122以第一角度延伸的侧面。第一角度能够例如在0度至90度之间的范围内。第二键形凹槽130能够具有从第二工件120的第一表面122以第二角度延伸的侧面，从而与第一键形凹槽130重叠。第二角度例如能够在90度至180度之间的范围内。
附加地或者替代地，在多键形凹槽实施例中，每个键形凹槽均能够参考其他键形凹槽130定位（例如角度136）。角度136例如能够在0至180度之间的范围内。
另外在多键形凹槽实施例中，至少一个键形凹槽130可以具有长度132。替代地，至少一个键形凹槽130的长度可以在大约10μm至大约1000mm之间变化。
可以使用冲压或其他机械和/或电气制造工艺将成形凹槽140插入到第二工件120中。如图1所示，成形凹槽140能够根据变化的几何形状（例如但不限于正方形、三角形、梯形、圆形和椭圆形）来形成。成形凹槽140与键形凹槽130相似地提供工件110、120之间的附加互锁。
成形凹槽140可以具有到第二工件120中的深度142。深度应该足以接收来自第一工件110的材料（例如，在大约10μm至大约100mm之间）。
在一些实施例中，成形凹槽140相对于第二工件120的第一表面122以一定角度定位。例如，如果成形凹槽140是梯形形状，则与第一表面122的角度144可以是锐角。然而，在成形凹槽140是倒三角形形状的情况下，与第一表面122的角度146可以是钝角。
可以使用化学品（例如，酸和金属腐蚀剂）切入到第一表面122中而将蚀刻凹槽150插入到第二工件120。蚀刻凹槽150可以形成为具有或不具有蚀刻掩膜（未示出）。
在蚀刻形成凹口的情况下，如图1所示，凹口的深度152可以使用已知蚀刻时间和腐蚀剂的已知蚀刻率来控制。在一些实施例中，蚀刻凹槽150底切蚀刻掩膜并且形成具有倾斜侧壁的凹口。深度152应该足以接收来自第一工件110的材料（例如在大约10μm至大约100mm之间）。
蚀刻凹槽150可以使用液相湿腐蚀剂（例如缓冲氢氟酸（HF）、磷酸（H3PO4）和硝酸（HNO3））或者等离子体相干腐蚀剂（例如四氯化碳（CCl4）、四氯化硅（SiCl4）和三氯化硼（BCl3））或者其他腐蚀剂来形成。例如，蚀刻凹槽150可以使用各向同性工艺或者各向异性工艺（包括磷酸）来形成，其中第二工件120的成分是铝。
在一些实施例中，凹槽130、140、150形成贯穿第一工件110或第二工件120的长度（未示出）的连续凹槽。在第一工件110和第二工件120之间期望连续连结的情况下，连续凹槽可能是期望的。例如在工件110、120承受剪切力和/或剥离力的情况下，可能期望连续接触。
在一些实施例中，向具有较低熔化温度的工件（例如图1中的第一工件110）添加附加材料。附加材料可以例如作为从第一工件的一个或两个表面延伸的一个或更多个凸起提供。在凹槽130、140、150具有特定长度和/或深度的情况下，第一工件110可能不包含足够的材料来填充凹槽130、140、150，从而使得在连结之后第一工件110的第一表面112具有缩痕。为了避免第一表面112上的缩痕，第一工件110可以包括附加材料来填充凹槽130、140、150。
附加材料可以定位在与第二工件120上的凹槽130、140、150对应的位置，从而允许附加材料直接流到凹槽130、140、150中。
在一个实施例中，附加材料包括铸造材料160，能够直接模制到第一工件110的第二表面114上。在另一实施例中，附加材料能够包括单独的材料170，其能够在制造过程期间附连到第一工件110的第二表面114上。替代地，可以在连结期间将单独的材料170引入。
铸造材料160和/或单独的材料170具有厚度165，厚度165足以填充凹槽130、140、150而不会在第一工件110的第一表面112上留下缩痕。厚度165能够直接地对应于凹槽130、140、150的长度和/或深度。例如，厚度165可以在大约10μm至大约100mm之间。
在第二工件120内形成的凹槽130、140、150中的任意一个可以在连结之前预先制造。另外，可以将铸造材料160和/或单独的材料170预先制造到第一工件110上或者附接到第一工件110上。
II.连结方法
连结系统100可以通过许多常规成形工艺形成，例如但不限于激光加热、感应加热和超声波焊接。每种工艺均示出为具有以上所述的示例凹槽130、140、150中的一个。然而，每种工艺均能够利用上述凹槽中的任意一个来促进连结工件110、120。
图2示出了使用激光加热工艺连结第一工件110和第二工件120。激光加热工艺在期望较短连结时间的大容量应用中是有益的。另外，由于激光具有集中的热覆盖区，所以激光加热工艺可以在需要在狭窄空间内进行连结的情况下使用。
在示例性激光加热工艺中，通过将第一工件110的第二表面114压缩（由箭头示出压缩力）接近第二工件120的第一表面122来形成接头，其中第二工件120具有比第一工件110高的熔化温度。然后激光束205在第二工件120的第二表面124上提供集中热量。第二工件120的集中加热形成了激光焊接区域200（在图2中示出为圆圈内区域），该区域200延伸到第一工件110从而使得第一工件110的材料熔化。在熔化时，例如由夹持产生的压缩压力迫使第一工件110的材料填充第二工件120内的键形凹槽130，从而形成接头。
图3示出了使用感应加热工艺连结第一工件110和第二工件120。在工件110、120包含导电材料（例如金属）的情况下，感应加热工艺是有益的。
在示例性感应加热工艺中，压缩力使得包括热塑性材料的第一工件110的第二表面114与包括传导性材料的第二工件120的第一表面122抵接。感应加热器305（例如加热线圈）使得电流（例如涡流）穿过第二工件120，并且电阻导致对第二工件120的第二表面124的加热。加热第二工件120形成感应焊接区域300（在图3中示出为圆圈内区域），该区域300延伸到第一工件110从而使得热塑性材料熔化。在熔化时例如由夹持产生的压缩压力迫使热塑性材料填充第二工件120内的成形凹槽140，从而形成接头。
替代地，感应加热器305能够使用与磁滞现象相关联的损耗来产生热。在第二工件120的材料具有渗透性的情况下，使用来自磁滞现象的损耗产生热会是有益的。
图4示出了使用超声波焊接工艺连结第一工件110和第二工件120。由于焊头405和砧座407的夹持力（如箭头所示）的原因，使得超声波焊接工艺可以产生具有增加强度的接头。在优选可见焊缝的情况下，可以使用超声波焊接。
在示例性超声波工艺中，焊接角405和砧407的压缩力使得第一工件110的第二表面114与第二工件120的第一表面122抵接。来自焊接角405的振动在第一工件110的第一表面112内产生热，从而形成超声波焊接区域400（在图4中示出为圆圈内区域）。超声波焊接区域400内的热量将第一工件110的材料熔化，熔化的材料填充第二工件120内的蚀刻凹槽150，从而形成接头。
III.图案–图5
在连结系统100中，凹槽130、140、150能够产生图5中看到的图案。附加地或者替代地，铸造材料160和/或单独的材料能够产生图5中看到的图案。在一些实施例中，凹槽130、140、150能够产生第一图案并且铸造材料160/单独的材料170能够形成对应于第一图案的第二图案，这促进了第一工件110和第二工件120的互锁。
如上所述的连结系统100可以包括凹槽130、140、150，其在工件110、120中的至少一个上具有随机图案，如随机分布510内所示。替代地，凹槽130、140、150可以在工件110、120之一内以对连结应用提供益处的图案形成。
在工件110、120中的至少一个的至少一个表面包含曲线特性（例如第一工件110是弯曲的）的情况下，图案可以在接头内提供附加强度。在一个实施例中，凹槽130、140、150形成平行线图案520，其中凹槽130、140、150沿着工件110、120中的至少一个的长度和/或宽度间隔开。在一个实施例，凹槽130、140、150形成交叉影线图案525以便在多于一个的方向上提供附加强度。
在一个实施例中，凹槽130、140、150形成连续线图案527。连续线图案527可以如图5所示由平行线构成。连续线图案也能够形成直线图案，例如交叉影线等等。
此外，在工件110、120中的至少一个具有几何形状（例如第一工件110是圆形的）的情况下，可以使用图案来在接头内提供附加强度。图案能够使用几何形状（例如正方形、圆形、椭圆形和三角形等等）来形成。
几何图案可以本质上是同心的，如图5的同心正方形图案530和同心圆形图案535所示。替代地，几何图案可以本质上是独立的，如独立的正方形图案540和独立的圆形图案545所示。
在一个实施例中，凹槽130、140、150形成连续的同心图案537或者连续的独立图案547。连续的同心图案537和连续的独立图案547能够形成如上所述的任意数量的几何形状。
其他图案也是可能的，并且根据应用对于系统设计者可以是优选的。
IV.本技术的选择特征
上文描述了本技术的许多特征。本部分概述地给出本技术的一些选定特征。本部分仅强调本技术的许多特征中的一些，并且以下段落不意味着是限制性的。
本技术的一个益处在于，通过在至少一个工件的连结表面上形成的凹槽所提供的机械互锁，而将工件可靠地连结。通过在工件上在连结表面处形成凹槽而产生机械互锁，这相对于没有凹槽而连结的工件，能够提高接头强度，例如剥离强度。
本技术的另一益处在于，能够针对特定的连结应用来改变凹槽的物理性质。凹槽的大小、形状和深度能够根据设计要求（例如强度或所需连结速度）而变化。另外，根据设计要求和/或工件形状，凹槽能够在工件内形成为图案。
本技术的另一益处在于，无需使用单独的机械互锁物品（例如粘合剂、铆钉或螺栓），就能够实现接头表面处的机械互锁。消除了对于单独的机械互锁物品的需要能够减轻接头的重量，并且提供不被螺栓/铆钉头中断的平滑的接头表面。
本技术的另一益处在于，通过单侧连结来实现平滑的接头表面。单侧连结使得在与接头表面相对的工件表面上不会留下任何可见的外观影响。消除对工件的可见影响允许自由的接头设计和自由的应用设计。
IV.结论
在此公开了本发明的各种实施例。所公开的实施例仅是示例，其可以以各种替代形式及其组合来实施。
在不脱离权利要求范围的情况下，可以对上述实施例进行变型、变更和组合。所有这样的变型、变更和组合都由本发明和所附权利要求的范围包括在本文中。

Claims (10)

1.一种用于在第一工件和第二工件之间形成接头表面的方法，包括：
提供所述第一工件的与第一表面相对的第二表面，用于与所述第二工件的第一表面接触，所述第二工件的第一表面与所述第二工件的第二表面相对，所述第二工件的第一表面具有形成在其中的凹槽；
向所述第一工件和所述第二工件中的至少一个施加能量，从而使得所述第一工件的材料熔化，产生熔融材料并且流入到形成在所述第二工件的第一表面中的所述凹槽中；以及
允许或使得所述熔融材料冷却，从而形成将所述第一工件连结到所述第二工件的互锁焊缝。
2.根据权利要求1所述的方法，其中形成所述系统还包括机械地、电气地或者通过化学蚀刻而将所述凹槽形成到所述第二工件的第一表面中。
3.根据权利要求1所述的方法，其中所述凹槽相对于所述第二工件的第一表面以90度至0度之间的角度延伸。
4.根据权利要求1所述的方法，其中:
所述第二工件的第一表面具有形成在其中的多个凹槽；
所述凹槽中的第一凹槽具有在参考系中从所述第二工件的第一表面以0度至90度之间的第一角度延伸的侧面，并且所述凹槽中的第二凹槽具有在所述参考系中从所述第二工件的第一表面以90度至180度之间的第二角度延伸的侧面；以及
在形成所述系统时施加的能量包括将所述第一工件的材料熔化，从而使得熔化的材料流入到在所述第二工件的第一表面中形成的所述凹槽的每个中，从而形成将所述第一工件连结到所述第二工件的互锁焊缝。
5.根据权利要求1所述的方法，其中:
在施加所述能量之前，所述第一工件包括从与所述第二工件的第一表面中的所述凹槽相对的第二表面延伸的凸起；并且
在形成所述系统时施加能量以将所述第一工件的材料熔化包括将所述凸起的至少一部分熔化，使其流入到所述凹槽中，从而形成将所述第一工件连结到所述第二工件的互锁焊缝。
6.根据权利要求1所述的方法，其中在形成所述系统时施加能量以将所述第一工件的材料熔化包括以下之一：应用激光来熔化所述第一工件的材料；应用感应来熔化所述第一工件的材料；以及应用超声波振动来熔化所述第一工件的材料。
7.一种系统，包括：
第一工件，包括第一表面和与所述第一表面相对的第二表面；以及
第二工件，包括第一表面，该第一表面与所述第一工件的第二表面通过互锁焊缝连接，并且具有形成在其中的形成所述互锁焊缝的一部分的凹槽；
其中所述系统通过以下来形成：
　　使得所述第一工件的第二表面与所述第二工件的第一表面接触；
　　向所述第一工件和所述第二工件中的至少一个施加能量，从而使得所述第一工件的材料熔化，产生熔融材料并且流入到在所述第二工件的第一表面中形成的所述凹槽中；以及
　　允许或使得所述熔融材料冷却，从而形成将所述第一工件连结到所述第二工件的互锁焊缝。
8.根据权利要求7所述的系统，其中形成所述系统还包括机械地、电气地或者通过化学蚀刻而将所述凹槽形成到所述第二工件的第一表面中。
9.根据权利要求7所述的系统，其中所述凹槽相对于所述第二工件的第一表面以90度至0度之间的角度延伸。
10.一种系统，包括：
第一工件，包括第一表面和与所述第一表面相对的第二表面；以及
第二工件，包括第一表面，该第一表面与所述第一工件的第二表面通过互锁焊缝连接，并且具有形成在其中的形成所述互锁焊缝的一部分的凹槽；
其中所述系统通过以下来形成：
　　使得所述第一工件的第二表面与所述第二工件的第一表面接触；
　　向所述第一工件和所述第二工件中的至少一个施加能量，从而使得所述第一工件的材料熔化，产生熔融材料，并且使在所述第二工件的第一表面中形成的所述凹槽的壁材料软化从而产生软化材料；以及
　　允许或使得所述第一工件的所述熔融材料流入到所述第二工件的所述凹槽中；以及
　　允许或使得所述第一工件的所述熔融材料和所述第二工件的所述凹槽的所述软化材料冷却，从而形成将所述第一工件连结到所述第二工件的互锁焊缝。
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