CN105916658A - 热塑性塑料的超声波焊接用的能量导向件接头的设计 - Google Patents

热塑性塑料的超声波焊接用的能量导向件接头的设计 Download PDF

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CN105916658A
CN105916658A CN201480060659.4A CN201480060659A CN105916658A CN 105916658 A CN105916658 A CN 105916658A CN 201480060659 A CN201480060659 A CN 201480060659A CN 105916658 A CN105916658 A CN 105916658A
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energy director
thermoplastic
fabric
film
ultrasonic welding
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CN105916658B (zh
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利奥·克林斯泰因
保罗·戈尔科
米兰达·贝尔·马库斯
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Duken IAS Ltd.
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Dukane IAS LLC
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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
    • B29C65/08—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
    • 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
    • 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
    • B29C66/114—Single butt 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
    • B29C66/302—Particular design of joint configurations the area to be joined comprising melt initiators
    • 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
    • B29C66/30223—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 said melt initiators being rib-like
    • 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
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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
    • 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
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
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    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/92—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/924—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/9261—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the displacement of the joining tools
    • B29C66/92611—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the displacement of the joining tools by controlling or regulating the gap between the joining tools
    • B29C66/92615—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the displacement of the joining tools by controlling or regulating the gap between the joining tools the gap being non-constant over time
    • 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
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    • B29C66/929—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges
    • B29C66/9292—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges in explicit relation to another variable, e.g. pressure diagrams
    • B29C66/92921—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges in explicit relation to another variable, e.g. pressure diagrams in specific relation to time, e.g. pressure-time diagrams
    • 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
    • B29C66/95—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94
    • B29C66/951—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 by measuring or controlling the vibration frequency and/or the vibration amplitude of vibrating joining tools, e.g. of ultrasonic welding tools
    • 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
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    • B29C66/1222—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a lapped joint-segment
    • 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
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    • B29C66/122—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
    • B29C66/1224—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a butt joint-segment
    • 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
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    • 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
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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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    • 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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    • B29C66/71—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
    • B—PERFORMING OPERATIONS; TRANSPORTING
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  • Mechanical Engineering (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)

Abstract

本发明公开了一种用于连接第一和第二热塑性塑料零件的超声波焊接系统和方法，包括形成在第一热塑性塑料零件的至少一个表面上的至少一个能量导向件，所述能量导向件从第一热塑性塑料零件的表面朝向第二热塑性塑料零件的相对面突出。所述能量导向件的远端部具有当第一和第二热塑性塑料零件彼此配合时与第二热塑性塑料零件的相对面初始配合的弯曲或平坦表面。通过当在平行于所述能量导向件的突出方向的方向上振动至少第一零件的同时将各零件按压在一起而超声波焊接第一和第二热塑性塑料零件。所述能量导向件可以包括与所述弯曲或平坦端面的相对端连接的一对基本上平坦的侧壁。

Description

热塑性塑料的超声波焊接用的能量导向件接头的设计
技术领域
本发明涉及一种热塑性塑料的超声波焊接，特别是焊接接头的设计。
背景技术
用于连接热塑性塑料零件的常用方法之一是超声波焊接，其涉及在零件被按压在一起的同时通过高频、小振幅振动来熔融相配合零件的表面。当足够量的熔融发生时，超声波振动终止，并且在保持零件上的压缩力的同时塑料固化，从而产生永久的组件。与其他连接方法相比，超声波焊接提供了包括速度、灵活性、清洁度和低成本的许多优势。
在超声波焊接的成功使用中，焊接接头的设计是一个重要的考虑因素；即，在焊接过程中将要连接的零件的那些熔融区域的几何形状。本领域技术人员已知许多不同的焊接接头设计，每种设计适于符合特定的焊接标准或者有利于某些材料的焊接的目的。
最常用的焊接接头设计之一是三角形能量导向件，由在其中一个零件上具有三角形轮廓并且在相配合零件上具有平坦表面的材料脊部组成。在图1～3的例子中示出了这种接头设计。图1示出了两个零件，包括能量导向件1a的零件1和包括平坦表面的零件2。图2是在焊接位置的零件的截面图，其中零件1的能量导向件的尖端与零件2的平坦表面接触。图3是图2的截面图的能量导向件区域的放大图。能量导向件的尖端较尖锐或稍微倒圆，以便在各零件之间提供较小的接触面积，从而允许在焊接开始时超声波振动集中而使熔融开始。三角形能量导向件在工业中一般简称为“能量导向件”，并且在诸如“Handbook of PlasticJoining”(第二版，Michael J.Troughton编著)等许多技术出版物中对其应用进行了详细介绍。
虽然三角形能量导向件设计已经被商业化使用许多年，但是有一些不希望的特点与其接头形状相关联。最显著的因素之一是包括能量导向件的零件模具的高制造成本。为了在尖端产生尖锐的边缘，能量导向件的几何形状通常通过在单块钢上的电火花加工(EDM)或将模具沿能量导向件的中心分割成其间具有密切控制间隙的两块来形成。前者的技术耗时并且涉及专用的工具，而后者需要严密的加工公差。因此，模具制造的成本相对较高。另一个缺点是在具有能量导向件的模制零件方面的挑战。具体地，在模制过程中很难用塑料完全填充尖锐的尖端。不完全或不一致的能量导向件能够反过来导致较弱的超声波焊接，或沿着整个接头路径不均匀的焊接。又一个缺点是能量导向件在焊接之前被损坏的易感性。在塑料零件被模制之后，它们经常被散装包装，然后运送到焊接台。如果包装方法允许能量导向件与其他零件接触，那么能量导向件的肋部可以被扭曲或粉碎，有时以高度局部化的方式。这种类型的缺陷可能导致用不足量的材料来形成连续焊接的区域，这在需要密封的情况下特别有问题。
发明内容
根据一个实施方案，提供了一种用于连接第一和第二热塑性塑料零件的超声波焊接系统。至少一个能量导向件形成在第一热塑性塑料零件的至少一个表面，并且所述能量导向件从第一热塑性塑料零件的表面朝向第二热塑性塑料零件的相对面突出。所述能量导向件的远端部具有当第一和第二零件彼此配合时与第二热塑性塑料零件的相对面初始配合的弯曲表面。通过当在平行于所述能量导向件的突出方向的方向上振动至少第一零件的同时将各零件按压在一起而超声波焊接第一和第二热塑性塑料零件。
在一个实施方式中，所述能量导向件的在垂直于将要由导向件配合的表面的方向上的纵截面在所述导向件的远端具有弯曲的轮廓。例如，所述弯曲的轮廓可以是具有中心的圆形部分，所述中心与第一热塑性塑料零件的所述能量导向件从其突出的表面基本上重合，或者在与所述能量导向件的突出方向相反的方向上或在与所述能量导向件的突出方向相同的方向上与第一热塑性塑料零件的所述能量导向件从其突出的表面间隔开。一对基本上平坦的侧壁可以连接到所述弯曲的轮廓的相对端，所述侧壁随着其远离所述弯曲的轮廓朝向所述热塑性塑料零件的其上形成所述能量导向件的表面延伸而彼此分开。所述弯曲的轮廓的最大宽度优选为所述能量导向件的纵截面的最大宽度的至少一半，并且所述弯曲的轮廓在所述能量导向件的远端优选具有至少0.20mm的曲率半径。
在另一个实施方案中，所述能量导向件的在垂直于将要由导向件配合的表面的方向上的纵截面具有基本上平坦的远端和连接到基本上平坦的远端的相对端的一对基本上平坦的侧壁，所述基本上平坦的侧壁随着其远离所述远端朝向第一热塑性塑料零件的将要被连接到第二热塑性塑料零件的表面延伸而彼此分开。
用于连接第一和第二热塑性塑料零件的超声波焊接方法包括：在第一热塑性塑料零件的至少一个表面上形成至少一个能量导向件，所述能量导向件从第一热塑性塑料零件的表面朝向第二热塑性塑料零件的相对面突出，所述能量导向件的端部具有当第一和第二热塑性塑料零件彼此配合时与所述相对面初始配合的弯曲或平坦表面，和通过当在平行于所述能量导向件的突出方向的方向上振动至少第一零件的同时将各零件按压在一起而超声波焊接第一和第二热塑性塑料零件。
所述能量导向件优选形成在模具中，在模具中形成所述能量导向件的空腔由球头铣刀形成。
在另一个实施方案中，用于将膜或织物连接到刚性热塑性塑料零件的超声波焊接方法包括：在刚性热塑性塑料零件的至少一个表面形成至少一个能量导向件，所述能量导向件从所述刚性热塑性塑料零件的表面朝向相对的膜或织物突出；所述能量导向件的端部具有当所述膜或织物与所述刚性热塑性塑料零件配合时与所述膜或织物初始配合的弯曲表面；和通过当在平行于所述能量导向件的突出方向的方向上振动所述刚性热塑性塑料零件或者所述膜或织物中的至少一个的同时将所述膜或织物和所述刚性热塑性塑料零件按压在一起而将所述膜或织物超声波焊接到所述刚性热塑性塑料零件。
附图说明
通过参考结合附图的以下说明可以最好地理解本发明，其中：
图1是用于超声波焊接的零件的分解立体图，其中之一包括三角形能量导向件。
图2是在超声波焊接位置的图1的零件的放大截面图。
图3是图2的零件的那些部分的进一步放大截面图。
图4是包括圆形能量导向件的零件的截面图，其中能量导向件的圆形部分的中心与从其突出的零件表面重合。
图5A和图5B是包括具有圆形远端表面的能量导向件的零件的截面图，圆形远端表面是具有在能量导向件从其突出的零件表面下方凹进(图5A)或从其上形成能量导向件的零件表面向前延伸(图5B)的中心的圆形的部分。
图5C和图5D是包括具有平坦远端的能量导向件的零件的截面图，其中能量导向件的平坦端面在随着朝向其上形成能量导向件的零件表面延伸而彼此分开的一对侧壁处终止(图5C)，或者在与随着朝向其上形成能量导向件的零件表面延伸而彼此分开的一对侧壁合并的一对倾斜角部处终止。
图6A和图6B是包括圆形能量导向件的零件的一对分解立体图。
图7是图6A的零件的截面图。
图8是在比较包括圆形能量导向件的零件的焊接质量和包括三角形能量导向件的零件的焊接质量的实验中焊接的两个代表性样品的距离随时间变化的一对曲线图。
图9是图8中记录的样品的力随时间变化的一对曲线图。
图10是图8中记录的样品的超声波功率随时间变化的一对曲线图。
尽管本公开易于做出各种修改和替代形式，但是具体实施方案或实施方式已经通过附图中的例子示出并且这里将进行详细地描述。然而，应当理解的是，本公开并非旨在限于所公开的特定形式。相反，本公开是为了涵盖由所附权利要求限定的落入本发明精神和范围内的所有修改、等同物和替代物。
具体实施方式
尽管本发明将结合某些优选实施方案进行描述，但是可以理解的是，本发明并不限于那些特定实施方案。相反，本发明旨在涵盖可以包括在由所附权利要求限定的本发明精神和范围内的所有替代物、修改和等同配置。
在图4的截面图中，包括能量导向件10a的第一塑料零件10将被焊接到第二塑料零件20。在本实施方案中，从第一零件10突出的能量导向件10a在导向件的远端具有弯曲的轮廓。在这个例子中，弯曲的轮廓呈半圆形的形状，圆形的中心基本上与第一热塑性零件10的能量导向件10a从其突出的表面重合。可选择地，圆形的中心可以从第一热塑性塑料零件的能量导向件从其突出的表面偏移(间隔开)。在图5A中，能量导向件10b的圆形的中心在与能量导向件的突出方向相反的方向上偏移距离X。在图5B中，能量导向件10c的圆形的中心在与能量导向件的突出方向相反的方向上偏移距离Y，并且能量导向件10c的轮廓还包括从零件10的平坦表面发出且在能量导向件的远端部的大致半圆形部处切向终止的平坦的锥形侧。能量导向件的轮廓的半圆形部的直径优选为在能量导向件从其发出的平坦的零件表面的平面中的能量导向件的宽度的至少一半。虽然在示出的实施方案中，零件10的邻近能量导向件的表面是平坦表面，但是可以理解的是，那些邻近的零件表面可以是不平坦表面。
在图5C中，能量导向件10d具有梯形的横截面轮廓，从而在能量导向件的远端上形成平坦表面。图5D示出了在图5C中所示的能量导向件的变型，其中在能量导向件10e的远端梯形的角部被截断，从而形成一对倾斜面。
具有弯曲或平坦远端轮廓的能量导向件适用于与先前的能量导向件相同的各种零件几何形状。在图6中示出了包括圆形能量导向件接头的简单零件的示例设计，其中图6A示出了具有圆形接头路径20a的零件20、零件21，图6B示出了具有矩形接头路径30a的零件30、零件31。在这两种构造中，在接头路径中的能量导向件与第一零件20或30一体，第二零件21或31包括平坦的相配合表面。
图7是图6A的截面图，示出了在焊接位置的零件，其中零件40的能量导向件的尖端与零件41的平坦表面接触。尽管图6和图7描绘了能量导向件与第一零件一体，但是其可以可选择地合并到第二零件中，而第一零件包括平坦表面。
在保留当开始焊接时在各零件之间提供较小的接触面积的特点的同时，具有弯曲或平坦远端轮廓的能量导向件相比于三角形设计提供了许多优势。首先，制造模具的时间和费用显著降低。使用标准的球头铣刀可以将单块钢直接磨成具有弯曲或平坦远端轮廓的能量导向件，从而消除对于特定工具或非常严密的加工公差的需要。另外，具有弯曲或平坦远端轮廓的能量导向件允许使用较大直径的切割工具，从而减少了加工时间和机床的主轴转速的要求。第二，基于与三角形能量导向件的尖端相比熔融的塑料更容易填充具有弯曲或平坦远端轮廓的能量导向件的空腔的事实，有利于零件模制过程，导致在焊接接头均匀性和零件-零件一致性中的改进，最终导致更均匀和一致的焊接结果。第三，具有弯曲或平坦远端轮廓的能量导向件比可比拟尺寸的三角形能量导向件更坚固，因此当在零件被模制的时间与被焊接的时间之间处理、包装和运送零件时，更不易损坏。由于损坏能量导向件(特别是在其尖端)的风险较小，所以生产率可以提高。
具有弯曲或平坦远端轮廓的能量导向件关于焊接质量的优点已经通过由焊接与图1所示的零件类似的两组圆形聚碳酸酯样品组成的实验所证实。在第一组中，盖子(图1中的零件1)包括具有图4所示轮廓的能量导向件，尖端半径为0.41mm。在第二组中，盖子包括图3所示的三角形能量导向件，高度为0.38mm，顶角为90°。基体(图1中的零件2)在这两组中是相同的。使用美国专利No.7,819,158中描述的伺服驱动的超声波压机以及采用美国专利No.8,052,816中描述的延迟动作技术，确定各样品组的焊接参数，以在维持相同的焊接塌陷距离的同时产生最优的焊接强度(即，拉伸断裂负荷)。对各组使用最优参数，对统计显著性数量的样品进行焊接，随后进行拉伸测试以测量焊接强度。对于第一能量导向件组，平均焊接强度和其用平均百分比表示的标准偏差分别为5220N和5.8％，而对于三角形能量导向件组，结果分别为4770N和10.6％。
图8～10是在上述实验中焊接的代表性样品的几个参数的曲线图，其中对于包括具有圆形端部轮廓的能量导向件的一个样品以及包括三角形能量导向件的一个样品，图8示出了距离随时间的变化，图9示出了力随时间的变化，图10示出了超声波功率随时间的变化。在各曲线图中，在时间＝0s时开始超声波振动。
这个实验的结果证实，本发明的能量导向件产生更一致的结果和更高的焊接强度。应当注意的是，由于暂停动作直到塑料材料的初始熔融发生以及在焊接过程中快速地改变力的能力，所以采用上述延迟动作技术的伺服驱动的超声波压机特别适于焊接包括具有弯曲或平坦远端轮廓的能量导向件的零件。
上述圆形能量导向件对于将膜或织物焊接到其上形成能量导向件的刚性热塑性塑料零件也是有用的。(将膜焊接到刚性塑料上在包装业中很普遍)。膜或织物通常通过将其直接在紧张状态下放置在其上形成能量导向件的刚性热塑性塑料零件上而位于超声波焊接的位置。可选择地，膜或织物可以支撑在未粘附到其上形成能量导向件的刚性热塑性塑料零件的表面上。从喇叭(超声波发生器)发出的用于将膜或织物焊接到刚性零件上的超声波振动可以施加到膜侧或刚性零件侧。
尽管已经阐述和描述了本公开的特定实施方式和应用，但是应当理解的是，本公开并不限于这里公开的精确的构造和组成，并且在不脱离所附权利要求限定的本发明精神和范围的情况下，各种修改、改变和变化从前述说明中可以是显而易见的。

Claims (16)

1.一种用于连接第一和第二热塑性塑料零件的超声波焊接方法，所述方法包括
在第一热塑性塑料零件的至少一个表面上形成至少一个能量导向件，所述能量导向件从第一热塑性塑料零件的表面朝向第二热塑性塑料零件的相对面突出，所述能量导向件的端部具有当第一和第二热塑性塑料零件彼此配合时与所述相对面初始配合的弯曲表面，和
通过当在平行于所述能量导向件的突出方向的方向上振动至少第一零件的同时将各零件按压在一起而超声波焊接第一和第二热塑性塑料零件。
2.根据权利要求1所述的超声波焊接方法，其中所述能量导向件的在垂直于将要由导向件配合的表面的方向上的纵截面在所述导向件的远端具有弯曲的轮廓。
3.根据权利要求2所述的超声波焊接方法，其中所述弯曲的轮廓是圆形部分。
4.根据权利要求3所述的超声波焊接方法，其中圆形的中心与第一热塑性塑料零件的所述能量导向件从其突出的表面基本上重合。
5.根据权利要求3所述的超声波焊接方法，其中圆形的中心在与所述能量导向件的突出方向相反的方向上与第一热塑性塑料零件的所述能量导向件从其突出的表面间隔开。
6.根据权利要求3所述的超声波焊接方法，其中圆形的中心在与所述能量导向件的突出方向相同的方向上与第一热塑性塑料零件的所述能量导向件从其突出的表面间隔开，并且包括连接到所述弯曲的轮廓的相对端的一对基本上平坦的侧壁，所述基本上平坦的侧壁随着其远离所述弯曲的轮廓朝向第一热塑性塑料零件的将要被连接到第二热塑性塑料零件的表面延伸而彼此分开。
7.根据权利要求2所述的超声波焊接方法，其中所述弯曲的轮廓的最大宽度为所述能量导向件的纵截面的最大宽度的至少一半。
8.根据权利要求2所述的超声波焊接方法，其中所述弯曲的轮廓在所述能量导向件的远端具有至少0.20mm的曲率半径。
9.根据权利要求1所述的超声波焊接方法，其中所述能量导向件形成在模具中，在模具中形成所述能量导向件的空腔由球头铣刀形成。
10.根据权利要求1所述的超声波焊接方法，其中所述能量导向件的在垂直于将要由导向件配合的表面的方向上的纵截面具有基本上平坦的远端和连接到基本上平坦的远端的相对端的一对基本上平坦的侧壁，所述基本上平坦的侧壁随着其远离所述远端朝向第一热塑性塑料零件的将要被连接到第二热塑性塑料零件的表面延伸而彼此分开。
11.根据权利要求10所述的超声波焊接方法，其中倾斜的角部将所述基本上平坦的远端连接到所述基本上平坦的侧壁。
12.一种用于将膜或织物连接到刚性热塑性塑料零件的超声波焊接方法，所述方法包括
在刚性热塑性塑料零件的至少一个表面形成至少一个能量导向件，所述能量导向件从所述刚性热塑性塑料零件的表面朝向所述膜或织物的相对面突出，所述能量导向件的端部具有当所述膜或织物与所述刚性热塑性塑料零件配合时与所述膜或织物初始配合的弯曲表面，和
通过当在平行于所述能量导向件的突出方向的方向上振动至少所述刚性热塑性塑料零件或者所述膜或织物的同时将所述膜或织物和所述刚性热塑性塑料零件按压在一起而将所述膜或织物超声波焊接到所述刚性热塑性塑料零件。
13.根据权利要求12所述的方法，其中所述膜或织物支撑在由未粘附到所述刚性热塑性塑料零件上的材料制成的刚性表面上。
14.一种用于连接第一和第二热塑性塑料零件的超声波焊接系统，所述系统包括
第一热塑性塑料零件，其具有从第一热塑性塑料零件的至少一个表面突出的至少一个能量导向件，
与所述能量导向件相对的第二热塑性塑料零件，其将要被焊接到第一热塑性塑料零件的所述能量导向件从其突出的表面，和
通过当在平行于所述能量导向件的突出方向的方向上振动至少第一零件的同时将各零件按压在一起而超声波焊接第一和第二热塑性塑料零件的装置，
其中所述能量导向件的远端部具有当第一和第二热塑性塑料零件彼此配合时与第二热塑性塑料零件的相对面初始配合的弯曲表面。
15.一种用于将膜或织物连接到刚性热塑性塑料零件的超声波焊接系统，所述系统包括
刚性热塑性塑料零件，其具有从所述刚性热塑性塑料零件的至少一个表面突出的至少一个能量导向件，
与所述能量导向件相对的膜或织物，其将要被焊接到所述刚性热塑性塑料零件的所述能量导向件从其突出的表面，和
通过当在平行于所述能量导向件的突出方向的方向上振动所述刚性热塑性塑料零件和所述膜或织物中的至少一个的同时将所述膜或织物和所述刚性热塑性塑料零件按压在一起而将所述膜或织物超声波焊接到所述刚性热塑性塑料零件的装置，
其中所述能量导向件的远端部具有当所述刚性热塑性塑料零件与所述膜或织物配合时与相对的膜或织物初始配合的弯曲表面。
16.根据权利要求15所述的系统，其中所述膜或织物支撑在由未粘附到所述刚性热塑性塑料零件上的材料制成的刚性表面上。
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