CN106079429B - 一种塑料板与铝板的电阻热铆焊方法 - Google Patents

一种塑料板与铝板的电阻热铆焊方法 Download PDF

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CN106079429B
CN106079429B CN201610450610.0A CN201610450610A CN106079429B CN 106079429 B CN106079429 B CN 106079429B CN 201610450610 A CN201610450610 A CN 201610450610A CN 106079429 B CN106079429 B CN 106079429B
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张昌青
吕广明
刘雄波
靳少龙
杨黎东
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Lanzhou University of Technology
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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
    • B29C65/72—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by combined operations or combined techniques, e.g. welding and stitching
    • 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
    • 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
    • B29C65/60—Riveting or staking
    • B29C65/601—Riveting or staking using extra riveting elements, i.e. the rivets being non-integral with the parts to be joined
    • B29C65/602—Riveting or staking using extra riveting elements, i.e. the rivets being non-integral with the parts to be joined using hollow rivets
    • 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
    • B29C66/40—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
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • 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

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  • Mechanical Engineering (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Connection Of Plates (AREA)

Abstract

一种塑料板与铝板的电阻热铆焊方法，其目的是实现不导电的塑料板和导电的铝板的焊接且解决单一胶结件有服役温度制约的缺陷，其步骤为：（1）塑料板（1）的厚度为t1，铝板（2）的厚度为t2，半空心铆钉（3）长度l≥t1+t2；半空心铆钉（3）的直径D=0.8~2.0t1，在搭接接头塑料板（1）侧打孔的直径等于半空心铆钉（3）的直径D；（2）焊接过程采用单级加压方式，其中焊接电流3.0kA~3.5kA，焊接时间13s~16s，电极压力0.22kN~0.27kN；设置如上参数后进行焊接，焊后将焊件取下。

Description

一种塑料板与铝板的电阻热铆焊方法
技术领域
本发明涉及压力焊技术领域，特别是涉及塑料板与铝板的电阻热铆焊技术。
背景技术
目前，随着汽车轻量化的发展加速，塑料在汽车中的应用变得越来越广泛。汽车轻量化使塑料作为原材料在汽车零部件制造领域被广泛应用。基于此背景要求，实现塑料与塑料及塑料与金属件的有效、可靠连接已经成为当下的研究热点。
经过检索现有技术发现，中国专利号CN100409995C，一种胶焊连接方法。这种方法是在两层待焊材料表面的搭接区域，涂上一层胶剂，然后采用熔化焊接热源进行搭接焊，以实现接头的良好的连接，该发明实现了机械结合、冶金结合和化学结合的有效统一使得结构件的承载载荷、疲劳强度和剪切强度有较大幅度的提高。然而这种方法得到的接头区域胶结区对于服役温度有严格要求，温度过高易易使胶结剂发生变性使得接头力学强度急剧降低。
经过检索现有技术，中国专利号CN 203879858U，塑料板材的铆钉加热电阻点焊结构。该发明是将同种塑料板材或熔点相近的异种塑料板材的双层或者多层搭接接头，由制定好的工艺规范确定需要打孔的位置和个数并在接头母材上预制一个直径等于铆钉直径的孔，以实现搭接接头的快速、有效及可靠地连接。这种方法只仅仅是针对于同种塑料板材或者熔点相近的异种塑料板材的连接，没有实现金属板材与塑料板材的连接，这对于实现汽车轻量化发展趋势的要求仍然是一个制约。
发明内容
本发明的目的是实现不导电的塑料板和导电的铝板的焊接且解决单一胶结件有服役温度制约的缺陷。
本发明是一种塑料板与铝板的电阻热铆焊方法，其步骤为：
（1）ABS塑料板1的厚度为t1，铝板2的厚度为t2，半空心铆钉3长度l≥t1+ t2；半空心铆钉3的直径D=0.8~2.0t1，在搭接接头ABS塑料板1侧打孔的直径等于半空心铆钉3的直径D；
（2）焊接过程采用单级加压方式，其中焊接电流3.0kA~3.5kA，焊接时间13s~16s，电极压力0.22kN~0.27kN；设置如上参数后进行焊接，焊后将焊件取下。
本发明的有益效果是：将电阻点焊、自冲铆接和胶结的有效结合且克服了塑料板材不导电的缺点同时在电极压力下铆钉穿透铝板实现自冲铆接并且在搭接表面塑料受热熔化形成胶结区，解决了单一胶结件有服役温度制约的缺陷同时实现了塑料板材和铝板材的有效可靠连接；本发明不需要在焊接前进行预制成型铆头等相对繁琐的工序，实现了塑料板和铝板的快速、有效及更可靠连接。
附图说明
图1为本发明的焊前结构图，图2为本发明的焊后结构图，附图标记及对应名称为：ABS塑料板1，铝板2，半空心铆钉3，上电极4，下电极5，焊后胶结区6。
具体实施方式
本发明是一种塑料板与铝板的电阻热铆焊方法，其步骤为：
（1）ABS塑料板1的厚度为t1，铝板2的厚度为t2，半空心铆钉3长度l≥t1+ t2；半空心铆钉3的直径D=0.8~2.0t1，在搭接接头ABS塑料板1侧打孔的直径等于半空心铆钉3的直径D；
（2）焊接过程采用单级加压方式，其中焊接电流3.0kA~3.5kA，焊接时间13s~16s，电极压力0.22kN~0.27kN；设置如上参数后进行焊接，焊后将焊件取下。
以上所述的塑料板与铝板的电阻热铆焊方法，半空心铆钉3为导电材质，且半空心铆钉3的硬度大于铝板2的硬度。
以上所述的塑料板与铝板的电阻热铆焊方法，接头的搭接次序是上部为ABS塑料板1，下部为铝板2。
以上所述的塑料板与铝板的电阻热铆焊方法，只需在搭接区域中心处ABS塑料板1上打孔。
下面结合附图和具体实施案例对本发明作进一步详细说明。
实施例1：
选取厚度为2mm的ABS塑料板1和厚度为1mm的工业纯铝板2，半空心铆钉为铁铆钉，其直径为3mm，长度为6mm；在ABS塑料板1的搭接区域中心处打孔，孔的直径为3mm，并清理孔周围的残屑等杂质。将半空心铁铆钉装配到预制的孔中并同时保证铁铆钉与纯铝板搭接表面充分接触以及铁铆钉与孔无隙接触。焊接时间13s，焊接电流3.0kA，电极压力为0.22kN。打开冷却水阀，将装配好的焊件放置在点焊机上、下电极间，保证焊件搭接区域中心铆钉与两电极处于同一条轴线上；通电进行焊接。焊前示意图及焊后示意图分别如图1和图2所示。
对焊接后得到的试样在岛津万能试验机上进行室温力学拉伸实验，结果表明：试样在塑料侧断裂，在铁铆钉处产生裂纹源并沿裂纹源在塑料板上向两侧扩展直至断裂；对其进行破坏实验发现铁铆钉穿透铝母材并围绕铁铆钉周围有一圈胶结区域存在。
实施例2：
选取厚度为2mm的ABS塑料板1和厚度为1mm的2A12铝合金板2，半空心铆钉为铁铆钉，其直径为2mm，长度为4mm；在ABS塑料板1的搭接区域中心处打孔，孔的直径为2mm，并清理孔周围的残屑等杂质。将半空心铁铆钉装配到预制的孔中并同时保证铁铆钉与铝合金板搭接表面充分接触以及铁铆钉与孔无隙接触。焊接时间16s，焊接电流3.5kA，电极压力为0.27kN。打开冷却水阀，将装配好的焊件放置在点焊机上、下电极间，保证焊件搭接区域中心铆钉与两电极处于同一条轴线上；通电进行焊接。焊前示意图及焊后示意图分别如图1和图2所示。
对焊接后得到的试样在岛津万能试验机上进行室温力学拉伸实验，结果表明：试样在铆钉处断裂；对其进行破坏实验发现铆钉未完全穿透铝合金母材且铆钉被镦粗，但围绕铁铆钉周围有一圈胶结区域存在。
实施例3：
选取厚度为2mm的ABS塑料板1和厚度为1mm的工业纯铝板2，半空心铆钉为不锈钢铆钉，其直径为4mm，长度为6mm；在ABS塑料板1的搭接区域中心处打孔，孔的直径为4mm，并清理孔周围的残屑等杂质。将半空心不锈钢铆钉装配到预制的孔中并同时保证不锈钢铆钉与纯铝板搭接表面充分接触以及不锈钢铆钉与孔无隙接触。焊接时间15s，焊接电流3.3kA，电极压力为0.25kN。打开冷却水阀，将装配好的焊件放置在点焊机上、下电极间，保证焊件搭接区域中心处的不锈钢铆钉与两电极处于同一条轴线上；通电进行焊接。焊前示意图及焊后示意图分别如图1和图2所示。
对焊接后得到的试样在岛津万能试验机上进行室温力学拉伸实验，结果表明：试样在不锈钢铆钉处断裂，对其进行破坏实验发现不锈钢铆钉穿透铝板同时围绕铆钉周围有一圈胶结区域存在。

Claims (4)

1.一种塑料板与铝板的电阻热铆焊方法，其特征在于，其步骤为：
（1）ABS塑料板（1）的厚度为t1，铝板（2）的厚度为t2，半空心铆钉（3）长度l≥t1+ t2；半空心铆钉（3）的直径D=0.8~2.0t1，在搭接接头ABS塑料板（1）侧打孔的直径等于半空心铆钉（3）的直径D；
（2）焊接过程采用单级加压方式，其中焊接电流3.0kA~3.5kA，焊接时间13s~16s，电极压力0.22kN~0.27kN；设置如上参数后进行焊接，焊后将焊件取下。
2.根据权利要求1所述的塑料板与铝板的电阻热铆焊方法，其特征在于：半空心铆钉（3）为导电材质，且半空心铆钉（3）的硬度大于铝板（2）的硬度。
3.根据权利要求1所述的塑料板与铝板的电阻热铆焊方法，其特征在于：接头的搭接次序是上部为ABS塑料板（1），下部为铝板（2）。
4.根据权利要求1所述的塑料板与铝板的电阻热铆焊方法，其特征在于：只需在搭接区域中心处ABS塑料板（1）上打孔。
CN201610450610.0A 2016-06-22 2016-06-22 一种塑料板与铝板的电阻热铆焊方法 Expired - Fee Related CN106079429B (zh)

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN2546179Y (zh) * 2002-06-26 2003-04-23 四川飞奇实业有限责任公司 瞬间加热铆合装置
CN104827661A (zh) * 2015-05-13 2015-08-12 兰州理工大学 一种热塑性塑料的铆钉加热连接方法

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EP2613924A1 (de) * 2010-09-09 2013-07-17 Basf Se Verfahren zur verbindung von mindestens zwei bauteilen
JP2013252648A (ja) * 2012-06-06 2013-12-19 Fukui Byora Co Ltd 締結方法

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN2546179Y (zh) * 2002-06-26 2003-04-23 四川飞奇实业有限责任公司 瞬间加热铆合装置
CN104827661A (zh) * 2015-05-13 2015-08-12 兰州理工大学 一种热塑性塑料的铆钉加热连接方法

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