CN105745058B - 纤维增强的塑料材料的接合方法 - Google Patents

纤维增强的塑料材料的接合方法 Download PDF

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CN105745058B
CN105745058B CN201580002670.XA CN201580002670A CN105745058B CN 105745058 B CN105745058 B CN 105745058B CN 201580002670 A CN201580002670 A CN 201580002670A CN 105745058 B CN105745058 B CN 105745058B
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couple
engagement
joint face
embedded part
concentrator
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CN105745058A (zh
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O·埃罗格卢
C·斯特凡齐奥萨
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Bayerische Motoren Werke AG
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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
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    • B29C66/72—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 structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
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    • 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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    • 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
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    • B29C66/3034—Particular design of joint configurations the joint involving an anchoring effect making use of additional elements, e.g. meshes
    • B29C66/30341—Particular design of joint configurations the joint involving an anchoring effect making use of additional elements, e.g. meshes non-integral with the parts to be joined, e.g. making use of extra elements
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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
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/45—Joining of substantially the whole surface of the articles
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/72—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 structure of the material of the parts to be joined
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    • B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/72—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 structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
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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
    • B29C66/73—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
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明涉及一种接合方法，用于借助超声波焊接法在纤维增强的由塑料材料制成的接合偶对(10、20)的连接面(11、21)上接合所述接合偶对，其中，在连接面(11，21)区域中在熔化之前在连接面(11，21)之间施加集中器(1)和/或至少一个埋件(2)，并且集中器(1)和/或埋件(2)与连接面(11、21)一起熔化，以致与连接面在硬化之后形成形状锁合的接合位置(3)，所使用的集中器(1)和/或埋件(2)包括纤维增强或颗粒增强的塑料材料。

Description

纤维增强的塑料材料的接合方法
技术领域
本发明涉及一种纤维增强的塑料材料的接合方法。本发明因此涉及一种接合方法，用于借助超声波焊接法在纤维增强的由塑料材料制成的接合偶对的连接面上接合、尤其是焊接所述接合偶对，在接合位置中埋入集中器和/或埋件以便提高连接强度。
背景技术
基于塑料材料的不断发展并且通过干净且简单地处理这些材料，可借助超声波焊接迅速建立热塑性材料的连接。借助超声波焊接建立的“不可分离的”连接可应用于不同的技术领域和不同塑料中。
在超声波焊接中，通过边界面摩擦和吸声，引入的振动在同时施加力的情况下转换成熔化热。接合材料在两个接合部件的焊接区中相互流入并且在冷却之后形成大致均匀的连接。接缝强度尤其是可通过振幅和/或力的分布来影响。
现有技术公开了用于借助超声波焊接的各种装置和方法。DE1804988B公开一种用于超声波焊接热塑性材料的装置，其中，具有伸长的顶点的超声波发生器与一个配合面相互压靠并且彼此相对设置，该装置可用于不同的材料形式，例如不同厚度且具有相对大尺寸的板状材料。借助这种装置尤其是也可彼此连接织物，所述织物由热塑性纤维制成或至少含有与天然纤维相结合的热塑性纤维，如聚酯纤维或棉花的混合物。
DE102010038470公开一种用于在工件之间建立材料锁合连接的方法，包括以下步骤：提供具有金属表面的工件，该工件至少在熔化面上具有涂层，所述涂层含有热塑性塑料；提供具有热塑性表面的工件；将熔化面与具有热塑性表面的工件相互贴靠；通过超声波作用在熔化面上焊接具有金属表面的工件和具有热塑性表面的工件。
DE2944080A公开一种超声波装置，用于焊接涂覆有塑料的金属箔、尤其是铝箔，所述装置包括超声波发生器和支承座，该超声波发生器借助在传统超声波焊接装置中常见的发射器和放大器激励，待焊接的箔放置在该支承座上。
此外，DE602004002051T2公开一种用于借助超声波来焊接热塑性材料的方法，其中，热塑性薄层具有至少一个孔，并且焊接仅在孔区域中进行。
AT0334616B公开一种用于借助超声波密封地连接由热塑性塑料制成的容器的方法，其中，材料在重叠中被焊接以便形成液密的包罩。
然而在现有技术中公开的方法具有各种缺点。一方面存在问题：在焊接不同熔点的塑料时产生不令人满意的焊接过程。
在焊接塑料时一个非常重要的方面在于连接位置的强度。尤其是在使用纤维增强塑料时需要焊接位置或者说接合位置具有足够高的强度和稳定性。
然而在焊接纤维增强塑料时已知，在软化和加热塑料时，处于纤维增强塑料中的连续纤维在边界面上不伸入接合位置中并且因此无助于连接强度。因此尽管使用纤维复合材料，但连接位置上的强度性能显著低于纤维复合材料的强度。
这意味着，连接位置是无颗粒增强或纤维增强的连接位置。
发明内容
因此本发明的任务在于，克服上述缺点并且提供一种改进的用于接合或者说焊接纤维增强的由塑料材料制成的接合偶对的方法，其中，接合位置具有改进的强度。
本发明的基本思想在于，在纤维增强的由塑料材料制成的接合偶对的接合位置中埋入单独的集中器和/或埋件，以便形成形锁合的和/或材料锁合的连接位置。
本发明的第一方面在于，将集中器、例如粒料形式的集中器埋入接合位置中，以便基于粒料熔化形成按规定构造的混合区域。
本发明的第二方面在于，代替集中器，使用熔化温度高于接合偶对熔化温度的埋件，以致埋件在连接面熔化时形锁合地埋入连接面中。
因此根据本发明提出一种接合方法，用于在纤维增强的由塑料材料制成的接合偶对的连接面上接合所述接合偶对，其中，在连接面区域中在连接面之间施加集中器，并且集中器与连接面一起借助超声波焊接法熔化，以致在硬化之后形成材料锁合的接合位置，该接合位置为由接合偶对的材料和集中器的材料构成的混合区域，所使用的集中器包括纤维增强或颗粒增强的塑料材料。
作为替代方案，还提出一种接合方法，用于在纤维增强的由塑料材料制成的接合偶对的连接面上接合所述接合偶对，其中，在连接面区域中在连接面之间施加埋件，并且借助超声波焊接法使连接面熔化，以致埋件形锁合地埋入连接面中并且因此获得形锁合的接合位置，所使用的埋件包括纤维增强或颗粒增强的塑料材料。优选这以下述方式进行，埋件的熔化温度高于接合偶对的熔化温度。由此，接合偶对的连接面熔化，并且埋件可形锁合地埋入连接面中。
因此，一方面可在真正的焊接过程之前在接合偶对之间的位置上施加以集中器和/或埋件形式的附加热塑性材料，在该位置上集中器和/或埋件用于按规定提高强度。按照本发明可根据接合目标灵活地使集中器或埋件的位置、用量和材料性能适应于工艺。
可能的集中器基体材料应具有与接合偶对类似的熔化范围和因此类似的熔化温度，以便能够建立足够稳定的连接。优选彼此焊接两种同类塑料，但例如也可接合由PA6制成的纤维增强塑料构件与由PA6.6或PA12制成的集中器。
根据本发明，这样设置超声波转换器和超声波发生器，以便使两个接合偶对通过机械振动而在它们的连接面上熔化并形成焊接连接。
此外优选接合偶对由热塑性塑料制成，在其中埋入大量连续纤维。通过这种方式，连续纤维增强的热塑性塑料可通过选择与适合的集中器连接，以便获得高强度的接合位置。
因此特别优选的是，所使用的集中器包括纤维增强或颗粒增强的塑料材料。通过这种方式可确保，在集中器熔化时也可在边界面和因此在接合位置中实现纤维增强。作为增强纤维或增强颗粒优选可使用碳纤维或玻璃纤维或者碳颗粒、玻璃纤维颗粒或类似物。
在本发明的另一种优选实施方式中规定，一个或多个埋件以相应适合的形状、尺寸和/或所选择的材料成分被埋入接合位置中。通过这种方式也可通过选择适合的埋件来形成复杂的接合过程。此外，还可通过不同的材料使用，并排设置埋件，并且在接合位置中利用通过埋件材料分别形成的技术优点。
在本发明的一种特别优选的实施方式中，通过适当地使用集中器和/或埋件实现接合位置在硬化之后形成上、下边界面以及位于它们之间的过渡区域，在此，埋件的大量增强纤维或元件从过渡区域通过至少一个边界面伸入接合偶对的相邻材料区域中，并且因此有助于连接强度。通过这种借助纤维增强的集中器或埋件建立的超声波焊接连接，获得的接合位置的强度显著高于按现有技术形成的接合位置的强度。
在本发明的一种优选实施方式中，提供作为粒料材料的集中器。在此情况下，粒料在接合偶对之间的熔化与接合面的熔化一起进行。
不同的材料适合用作埋件。因此作为埋入材料例如可使用CFRTP或作为替代方案使用金属埋件、如精冲构件。作为CFRTP，例如可使用碳纤维增强的热塑性埋件，该埋件直接埋入接合偶对的接触面之间并且通过机械振动与接合偶对一起熔化并且在硬化之后成为焊接连接的一部分。
本发明的另一方面在于，作为集中器材料或埋件材料可分别使用具有特殊技术性能的塑料材料，从而可利用这些性能。
附图说明
本发明的其它优选扩展方案在下面参考附图结合本发明的优选实施例的说明来详细描述。附图如下：
图1为超声波焊接装置的示意图，其中，使用纤维增强或颗粒增强的热塑性粒料形式的集中器；
图2为超声波焊接装置的与图1类似的示意图，其中，代替集中器，在接合位置中埋入形状稳定的埋件，该埋件的熔化温度高于接合偶对的熔化温度；
图3为两个接合偶对的借助本发明方法制造的接合位置的示意性剖面图。
具体实施方式
下面参考图1至3说明本发明的方法，在此，相同附图标记表示相同的功能和结构元件。
根据本发明的方法基于超声波焊接法借助超声波装置30实施。超声波焊接装置30包括传统的超声波换能器31和超声波发生器32，该超声波发生器可以以力F压到接合偶对上。通过超声波焊接装置30可在两个接合偶对10、20的边界面上实现超声波振动。在产生超声波振动时，接合偶对10、20的连接面11、21连续熔化。在平面式的接合面接近并且直至两个接合偶对10、20完全耦合之前，在接合偶对10、20之间，而且是在它们的连接面11、21之间，如图1所示，放入集中器1。
作为替代方案，在图2所示方法中，在接合位置中埋入碳纤维增强的热塑性的埋件2。该埋件2的熔化温度高于接合偶对的熔化温度，以致于埋件在接合偶对借助超声波熔化时保持形状稳定并且因此形锁合地埋入到接合位置中。
根据本发明另外规定，基于静态的熔融性能形成恒定或符合规定的熔体层厚度，该熔体层厚度可通过超声波发生器的振幅或通过力分布来影响。在形成足够厚的熔体层厚度之后，停止超声波加载并且固化焊接区，从而形成形锁合的接合位置3，该接合位置分别具有上、下边界面3a、3b并且熔化的区域——由边界面之间熔化的熔体层厚度决定——构成过渡区域3c，如图3中示意性示出。在过渡区域3c中存在所使用集中器的大量增强纤维3d，这些增强纤维分别通过相邻的边界面3a、3b伸入连续纤维增强的热塑性的塑料接合偶对10、20的相邻材料区域中并且因此有助于连接强度。
本实施例可借助连续纤维增强的热塑性聚酰胺来实施。作个集中器1，例如可使用粒料形式的纤维增强聚酰胺PA66。
本发明的实施不局限于上面所给出的优选实施例。更多地，可想到多种变型方案，它们利用所描述的解决方案，尽管是在原则上不同方式的实施中。

Claims (10)

1.接合方法，用于在纤维增强的由塑料材料制成的接合偶对(10、20)的连接面(11、21)上接合所述接合偶对，其中，在连接面(11、21)区域中在连接面之间施加集中器(1)，并且集中器与连接面(11、21)一起借助超声波焊接法熔化，以致在硬化之后形成材料锁合的接合位置(3)，该接合位置形成为由接合偶对的材料和集中器的材料构成的混合区域，所使用的集中器(1)包括纤维增强或颗粒增强的塑料材料，
所述接合位置(3)在硬化之后包括上、下边界面(3a、3b)和过渡区域(3c)，在过渡区域(3c)中存在大量增强纤维(3d)，所述大量增强纤维从过渡区域(3c)通过至少一个边界面(3a、3b)伸入接合偶对(10、20)的相邻材料区域中并且有助于连接强度。
2.根据权利要求1的方法，其特征在于，所述接合偶对(10、20)由热塑性塑料制成，在接合偶对中埋入大量连续纤维。
3.根据权利要求1的方法，其特征在于，作为增强纤维或增强颗粒，使用碳纤维或玻璃纤维，或使用由碳纤维或玻璃纤维制成的颗粒。
4.根据权利要求1至3之一的方法，其特征在于，作为集中器，使用塑料粒料。
5.接合方法，用于在纤维增强的由塑料材料制成的接合偶对(10、20)的连接面(11、21)上接合所述接合偶对，其中，在连接面(11、21)区域中在连接面之间施加埋件(2)，并且连接面(11、21)借助超声波焊接法熔化，以致埋件(2)形锁合地埋入连接面中并且因此获得形锁合的接合位置(3)以及在埋件之间获得材料锁合的接合位置，所使用的埋件(2)包括纤维增强或颗粒增强的塑料材料，
所述接合位置(3)在硬化之后包括上、下边界面(3a、3b)和过渡区域(3c)，在过渡区域(3c)中存在大量增强纤维(3d)，所述大量增强纤维从过渡区域(3c)通过至少一个边界面(3a、3b)伸入接合偶对(10、20)的相邻材料区域中并且有助于连接强度。
6.根据权利要求5的方法，其特征在于，所述接合偶对(10、20)由热塑性塑料制成，在接合偶对中埋入大量连续纤维。
7.根据权利要求5的方法，其特征在于，作为增强纤维或增强颗粒，使用碳纤维或玻璃纤维，或使用由碳纤维或玻璃纤维制成的颗粒。
8.根据权利要求5至7之一的方法，其特征在于，不同形状和/或不同材料成分的多个埋件(2)埋入接合位置(3)中。
9.根据权利要求5至7之一的方法，其特征在于，所述埋件(2)的熔化温度高于接合偶对(10、20)的熔化温度。
10.根据权利要求8的方法，其特征在于，所述埋件(2)的熔化温度高于接合偶对(10、20)的熔化温度。
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