CN106273414A - 一种塑料与金属永久性直接连接的制备方法 - Google Patents
一种塑料与金属永久性直接连接的制备方法 Download PDFInfo
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Abstract
本发明涉及金属与塑料焊接技术领域,具体地指一种塑料与金属永久性直接连接的制备方法。利用激光光束照射金属部件的表面在金属部件的表面烧蚀出呈蜂窝状分布的多个连接孔,将塑料部件的连接面与金属部件的表面贴合,使熔化的液态塑料进入到连接孔中,待进入到连接孔中的塑料冷却后金属部件和塑料部件完成焊接连接。本发明的焊接方法利用高峰值功率、高光束质量、短脉冲激光光束处理金属表面,在表面形成微结构蜂窝孔,微孔直径、深度和填充密度都可以灵活控制,可根据实际需求进行相应的调整,适应性更好。
Description
技术领域
本发明涉及金属与塑料焊接技术领域,具体地指一种塑料与金属永久性直接连接的制备方法。
背景技术
随着汽车、手机、电脑、家电等技术的快速发展,设备及元件轻量化要求越来越高,金属具有质感光泽、良好的导电性能,而塑料具有密度小、质量轻而且绝缘性能好的特征。将塑料与金属结合越来越广泛地应用在机械及电子制造领域。为了实现塑料与金属的完美结合目标,各行各业都做了很多尝试与努力,具有代表性的工艺有胶粘、电镀、铆接、金属嵌件注塑以及NMT技术等。胶粘技术强度有限,且不能保证永久性连接,使用时间一长就会出现金属与塑料连接部位出现断裂的现象。
金属嵌件注塑技术专利如专利号为“CN200710200616”的名为“金属件与塑料件的连接结构”的中国实用新型专利和专利号为“CN201080067868”的名为“金属塑料连接”的中国实用新型专利,嵌件注塑技术通常是先加工好金属部件,使金属部件具有与塑料部件的连接结构,然后在该连接结构的基础上注塑成型塑料部件,这样才能够完成金属与塑料的连接。这种方式得提前加工好金属部件,而金属的加工比较耗费工时,导致整个连接的效率大幅度降低,成本大幅度升高,不利于推广应用。
铆接技术专利号为“CN201610167498”的名为“一种使塑料和金属良好连接的超声波金属铆焊方法”的中国发明专利,铆接技术通常需要在金属部件上加工出销钉结构,在塑料部件上加工出对应的销孔结构,焊接时将销钉插入到销孔内,再进行熔化或是其他处理,将两 者固定在一起,这种方式连接的很紧密,但是由于需要提前加工出对应的结构部件,同样增加了零部件处理的工时,增加了部件连接的成本,不利于推广运行。
另一种不同视角比较先进的方法NMT技术如专利号为“US20110250377”的名为“System and method for plastic overmolding on a metal surface”的美国发明专利,该方法先使用化学腐蚀的方式对金属表面进行处理,将金属表面腐蚀出纳米级微孔结构,后在金属表面注塑塑料元件,适用于各种厚度、不限于元件尺寸但连接强度有限难以进一步提高,另外,该技术使用到了化学工艺,不够环保,难以针对元件的局部处理。
发明内容
本发明的目的就是要解决上述背景技术的不足,提供一种塑料与金属永久性直接连接的制备方法。
本发明的技术方案为:一种塑料与金属永久性直接连接的制备方法,其特征在于:利用激光光束照射金属部件的连接面在金属部件的连接面烧蚀出呈蜂窝状分布的多个连接孔,将塑料部件的连接面与金属部件的连接面贴合,对塑料部件的连接面进行加热使熔化的液态塑料进入到连接孔中,待进入到连接孔中的塑料冷却后金属部件和塑料部件完成焊接连接。
进一步的所述的方法包括以下步骤:
1)、利用激光光束照射金属部件的连接面,使照射部位的金属气化产生空化效应形成连接孔,反复照射金属部件使其连接面布满呈蜂窝状分布的多个连接孔;
2)、将塑料部件的连接面与金属部件的连接面紧密贴合在一起,加热使塑料部件的连接面熔化,加压迫使熔化的液态塑料进入到连接孔内;
3)、对金属部件和塑料部件的连接部位进行冷却,使进入到连接孔内的塑料凝固完成金属部件与塑料部件的焊接连接。
进一步的步骤1中,使用的激光光束的波长为355~360nm,平均功率为10~15W,脉冲宽度为15~20ns,重复频率为40kHz,光束质量因子M2为1.5,激光光束照射在金属部件的连接面上的光斑的直径为0.02~0.05mm。
进一步的步骤1中,每个连接孔由至少一个脉冲的激光光束烧蚀而成。
进一步的所述的连接孔与纵向和/或横向的相邻的连接孔连通
进一步的通过激光光束照射金属部件的连接面在连接面上开设有连接孔的区域的外围烧蚀出多个与该区域的最外围的连接孔连通的排气孔。
进一步的开设有连接孔的金属部件的连接面的面积大于与金属部件的连接面贴合在一起的塑料部件的连接面的面积。
进一步的塑料部件的连接面的加热方法为:使用热源对金属部件的连接面的背面进行加热,通过热传导的方式将热量传递到塑料部件的连接面上使塑料部件的连接面熔化。
进一步的塑料部件的连接面的加热方法为:将热源布置在塑料部件的连接面的背面,热量穿透塑料部件作用至塑料部件与金属部件的连接部位上,使塑料部件的连接面熔化。
进一步的所述的热源为红外激光热源,其波长为980nm,对金属部件与塑料部件的连接部位的加热温度为220~250℃。
进一步的所述的步骤2可以替换为:将模具紧密贴合在金属部件的连接面上,向模具内注塑液态塑料形成塑料部件,贴合在金属部件的连接面上的液态塑料渗透到连接孔内连接金属部件和塑料部件。
进一步的所述的连接孔的深度为0.05~0.1mm,其直径为0.02~0.05mm。
本发明的优点有:利用本发明塑料与金属永久性直接连接的制备方法与现有胶粘、铆接、嵌件及NMT技术方法相比,增强了塑料与金属连接的结合强度,保证永久性牢固结合,适用于厚度、体积更加灵活的结构,并且无化学工艺过程更加环保。
与胶粘技术相比,本发明的方法解决了胶粘方法的牢固性较差、固化时间较长、不能长期有效的问题。
与铆接、嵌件技术相比,本发明的方法解决了铆接、嵌件方法的体积较大、厚度较厚的问题,能够适用于厚度更薄、体积更小的金属和塑料的连接,且金属部件的表面处理方式更加简单,提高了焊接连接的效率。
与NMT技术相比,本发明的方法解决了其连接强度有限、化学工艺不环保、不能局部表面处理的问题,并且NMT技术只适合注塑生长工艺,不适合二次加热焊接连接工艺。
本发明的焊接方法利用高峰值功率、高光束质量、短脉冲激光光束处理金属表面,在表面形成微结构蜂窝孔,微孔直径、深度和填充密度都可以灵活控制,可根据实际需求进行相应的调整,适应性更好。
附图说明
图1:激光光束处理金属部件表面的结构示意图;
图2:金属部件连接面上的连接孔布置结构示意图;
图3:热源位于金属部件的连接面的背面的结构示意图;
图4:热源位于塑料部件的连接面的背面的结构示意图;
图5:塑料部件与金属部件的贴合结构示意图;
图6:直接在金属部件的连接面上注塑塑料部件的结构示意图;
其中:1—激光光源;2—激光光束;3—扫描振镜;4—扫描透镜;5—金属部件;6—连接孔;7—塑料部件;8—加持盖板;9—支撑平台;10—排气孔;11—注塑塑料;12—热源;13—注塑模具。
具体实施方式
下面结合附图和具体实施例对本发明作进一步的详细说明。
如图1~6,本实施例对金属部件和塑料部件进行焊接连接的方式为:
步骤1:如图1所示,由激光光源1发出可以对金属部件的表面 进行处理的激光光束2,本实施例的激光光束2的波长为355nm,平均功率为10W,脉冲宽度20ns,重复频率40kHz,光束质量因子M2为1.5,本实施例的激光光束2具有较强的加工能力,能够加工大多数金属材料。激光光束2经过扫描振镜3和扫描透镜4(振镜用于改变激光光束2的方向,透镜用于聚焦激光光束2,同时移动振镜和透镜就能够将聚焦的激光光束2按照设定的方向前进),聚焦到待加工的金属部件5表面,聚焦光斑大小在0.02~0.05mm,因此在金属部件5的表面加工出的连接孔的孔径为0.02~0.05mm,扫描透镜的布置主要是控制激光光束2的摆动,通过控制扫描振镜3的摆动速度控制聚焦光斑的移动速度。
激光光束2照射在金属部件的连接面上的聚焦光斑需要不断的移动才能在金属部件的连接面上加工出蜂窝状的连接孔,聚焦光斑不能在一个位置停留太长时间,否则会烧蚀出不符合要求的连接孔影响金属部件和塑料部件的焊接。调节聚焦光斑需要根据激光光束2的能量和加工的材质来确定,本实施例加工的金属材料为304不锈钢,根据激光光束2的特性,聚焦光斑的移动速度在1800~2000mm/s时,刚好能够加工出符合要求的连接孔。
为了便于液态塑料充分浸润到每一个连接孔中,本实施例要求连接孔至少与其相邻的一个或是多个连接孔连通,因此激光光束2加工金属部件5的连接面时,需要聚焦光斑与相邻的连接孔6有重叠。当聚焦光斑的移动速度在1800~2000mm/s时,刚好能够加工出连接孔6相互连通的金属表面。
本实施例激光光束对金属部件5的连接面蚀刻的深度为0.05~0.1mm,直径为0.02~0.05mm,实际情况下,可根据材料的特性进行相应的调整。
步骤2:如图2所示,将塑料部件7的连接面与金属部件5的连接面紧密贴合在一起。为了保持紧密的贴合关系,本实施例需要对两个部件施加压力,保证塑料部件7的连接面与金属部件5的连接面上开设有连接孔6的部位紧密贴合在一起。同样的保持紧密的贴合能够保证液态塑料能够充分浸润到每一个连接孔6中,增强了金属部件5和塑料部件7的连接紧密性。
如图3所示,本实施例将金属部件5放置在支撑平台9之上,塑料部件7的上面用夹持盖板8压住,夹持盖板8的材料为石英玻璃,同样具有良好的光学特性,通过夹持盖板8施加持续压力,使塑料部件7和金属部件5紧密贴合。然后加热使塑料部件7与金属部件5的连接部位熔化。
本实施例使用的热源12为近红外激光,波长980nm,能够有效穿透石英玻璃8辐照金属部件5的表面,为了使受热更加均衡,本实施例将热源12布置在金属部件5的连接面的背面,通过热传导的方式将热传递到塑料部件7的连接面上,迫使塑料部件7的连接面的温度上升到220~250℃,即塑料部件7的熔点,使塑料部件7的连接面开始熔化,在压力和自身膨胀的作用下渗入金属部件5表面的连接孔6内。
液态塑料进入到连接孔6内后,连接孔6内有空气,如果空气不能完全排除干净,其连接部位会出现孔隙导致连接不紧密,因此,如图5所示,本实施例的金属部件5上开设有连接孔6的连接面的面积要大于塑料部件7的连接面贴贴合在金属部件5上的面积,两者连接部位外面还应该有一些没有贴合在塑料部件的连接面上的连接孔6,实际上为了保证气体的充分排放,本实施例还在连接孔的最外围位置开设有一些排气孔10,如图3、4和6所示。当液态塑料进入到连接孔6中后,由于连接孔6都是连通的,空气从最外侧的连接孔6(或是排气孔10)排出,避免连接部位产生孔隙影响焊接结构强度。
若焊接的塑料部件7为透明材料,可以直接使用热源12照射塑料部件7的连接面的背面,红外激光可以透过塑料部件7直接作用在两者的连接部位,这样的作用方式热量散逸的更少,热量更加集中,有利于焊接的进行。
而对于部分热塑性较差或者熔化温度与热分解温度很接近的塑料,上述的二次辐照加热方法适用性不强,可采用直接注塑生长的方 法,如图6所示。经过激光表面处理后的不锈钢金属部件5放置在支撑平台9上面,注塑模具13放置在金属部件5上面,并施加持续的压力,熔化态的PBT注塑塑料11注入模具13,并可以渗入金属部件5表面的连接孔内,多余的空气可以从边沿的连接孔中排出,减小内部压力利于塑料充分渗入金属表面的连接孔内。
步骤3:对金属部件5和塑料部件7的连接部位进行降温冷却,使进入到连接孔6中的塑料凝固将两者粘贴在一起,完成焊接连接。
以上显示和描述了本发明的基本原理、主要特征和本发明的优点。本行业的技术人员应该了解,本发明不受上述实施例的限制,上述实施例和说明书中描述的只是说明本发明的原理,在不脱离本发明精神和范围的前提下本发明还会有各种变化和改进,这些变化和改进都落入要求保护的本发明范围内。本发明要求保护范围由所附的权利要求书及其等同物界定。
Claims (8)
1.一种塑料与金属永久性直接连接的制备方法,其特征在于:利用激光光束(2)照射金属部件(5)的连接面在金属部件(5)的连接面烧蚀出呈蜂窝状分布的多个连接孔(6),将塑料部件(7)的连接面与金属部件(5)的连接面贴合,对塑料部件(7)的连接面进行加热使熔化的液态塑料进入到连接孔(6)中,待进入到连接孔(6)中的塑料冷却后金属部件(5)和塑料部件(7)完成焊接连接。
2.如权利要求1所述的一种塑料与金属永久性直接连接的制备方法,其特征在于:所述的方法包括以下步骤:
1)、利用激光光束(2)照射金属部件(5)的连接面,使照射部位的金属气化产生空化效应形成连接孔(6),反复照射金属部件(5)使其连接面布满呈蜂窝状分布的多个连接孔(6);
2)、将塑料部件(7)的连接面与金属部件(5)的连接面紧密贴合在一起,加热使塑料部件(7)的连接面熔化,加压迫使熔化的液态塑料进入到连接孔(6)内;
3)、对金属部件(5)和塑料部件(7)的连接部位进行冷却,使进入到连接孔(6)内的塑料凝固完成金属部件(5)与塑料部件(7)的焊接连接。
3.如权利要求1或2所述的一种塑料与金属永久性直接连接的制备方法,其特征在于:所述的连接孔(6)与纵向和/或横向相邻的连接孔(6)连通。
4.如权利要求1或2所述的一种塑料与金属永久性直接连接的制备方法,其特征在于:通过激光光束(2)照射金属部件(5)的连接面在连接面上开设有连接孔(6)的区域的外围烧蚀出多个与该区域的最外围的连接孔(6)连通的排气孔(10)。
5.如权利要求1或2所述的一种塑料与金属永久性直接连接的制备方法,其特征在于:开设有连接孔(6)的金属部件(5)的连接面的面积大于与金属部件(5)的连接面贴合在一起的塑料部件(7)的连接面的面积。
6.如权利要求1或2所述的一种塑料与金属永久性直接连接的制备方法,其特征在于:塑料部件(7)的连接面的加热方法为:使用热源(12)对金属部件(5)的连接面的背面进行加热,通过热传导的方式将热量传递到塑料部件(7)的连接面上使塑料部件(7)的连接面熔化。
7.如权利要求1或2所述的一种塑料与金属永久性直接连接的制备方法,其特征在于:塑料部件(7)的连接面的加热方法为:将热源(12)布置在塑料部件(7)的连接面的背面,热量穿透塑料部件(7)作用至塑料部件(7)与金属部件(5)的连接部位上,使塑料部件(7)的连接面熔化。
8.如权利要求2所述的一种塑料与金属永久性直接连接的制备方法,其特征在于:所述的步骤2可以替换为:将模具(13)紧密贴合在金属部件(5)的连接面上,向模具(13)内注塑液态塑料形成塑料部件(7),贴合在金属部件(5)的连接面上的液态塑料渗透到到连接孔(6)内连接金属部件(5)和塑料部件(7)。
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