CN1113466A - 镀有金属的塑料的超声波焊接 - Google Patents

镀有金属的塑料的超声波焊接 Download PDF

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CN1113466A
CN1113466A CN95102006A CN95102006A CN1113466A CN 1113466 A CN1113466 A CN 1113466A CN 95102006 A CN95102006 A CN 95102006A CN 95102006 A CN95102006 A CN 95102006A CN 1113466 A CN1113466 A CN 1113466A
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plastics
working
welded joint
welding
welded
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CN1050565C (zh
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安德烈泽·T·古兹克
史蒂芬·D·亨特
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Motorola Solutions Inc
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Motorola Inc
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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
    • 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
    • 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
    • B29C65/82—Testing the joint
    • B29C65/8207—Testing the joint by mechanical methods
    • B29C65/8215—Tensile tests
    • 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
    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/124—Tongue and groove joints
    • B29C66/1244—Tongue and groove joints characterised by the male part, i.e. the part comprising the tongue
    • B29C66/12441—Tongue and groove joints characterised by the male part, i.e. the part comprising the tongue being a single wall
    • 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
    • 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
    • B29C66/32—Measures for keeping the burr form under control; Avoiding burr formation; Shaping the burr
    • B29C66/322—Providing cavities in the joined article to collect the burr
    • 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
    • B29C66/341—Measures for intermixing the material of the joint interlayer
    • 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
    • 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
    • B29C66/72—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
    • B29C66/723—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 being multi-layered
    • B29C66/7232—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 being multi-layered comprising a non-plastics layer
    • B29C66/72321—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 being multi-layered comprising a non-plastics layer consisting of metals or their alloys
    • 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
    • B29C66/73—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
    • 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
    • B29C66/71—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
    • 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
    • B29C66/71—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
    • 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
    • B29C66/73—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
    • B29C66/731—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 intensive physical properties of the material of the parts to be joined
    • B29C66/7311—Thermal properties
    • B29C66/73115—Melting point
    • 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
    • B29C66/73—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
    • B29C66/737—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 state of the material of the parts to be joined
    • B29C66/7377—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 state of the material of the parts to be joined amorphous, semi-crystalline or crystalline
    • B29C66/73771—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 state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being amorphous
    • B29C66/73772—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 state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being amorphous the to-be-joined areas of both parts to be joined being amorphous
    • 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
    • B29C66/73—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
    • B29C66/737—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 state of the material of the parts to be joined
    • B29C66/7377—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 state of the material of the parts to be joined amorphous, semi-crystalline or crystalline
    • B29C66/73773—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 state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being semi-crystalline
    • B29C66/73774—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 state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being semi-crystalline the to-be-joined areas of both parts to be joined being semi-crystalline
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    • 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
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    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • 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
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products
    • B29L2009/005—Layered products coated
    • B29L2009/008—Layered products coated metalized, galvanized
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
    • Y10T156/1043—Subsequent to assembly

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)

Abstract

一种用超声波将两塑料件焊成一体的方法。一 塑料件30的焊接接合部23覆盖有金属层27，另一 塑料件25有互补的焊接接合部。用超声波将两接 合部相互焊接，将两件连成一体。焊前在两塑料件上 施加力40，它显著大于使两焊接接合部彼此接触所 需的力。该方法生产出一种超声波焊接的镀有金属 的塑料组件，组件的每一件都有一焊接接合部，至少 一接合部焊前覆盖有一金属层。两接合部的每一部 分都发生变形，以形成穿过金属层的塑料焊接连接。

Description

本发明总地说涉及一种连接两零件的方法，更具体地说，涉及塑料件的超声波焊接。
超声波焊接允许准确而精密地利用能量，有选择地熔接或焊接塑料组件的指定部位。超声波装置适用于大多数热塑性塑料，并广泛用汽车，包装，电子和消费工业中的热塑性塑料件焊接。在实践中，借助超声波焊机将高频（超声波）机械振动传给配合的塑料零件。在两零件的接合部或接合面处施加的力和表面和/或分子间的摩擦的复合作用使温度升高，直至达到热塑性塑料的熔点为止，然后卸去超声波能量，两塑料零件间便产生分子连接或焊接。
超声波焊接系统典型地含有一高频能源（通常为20-40KHZ）。高频能量传入一触头，该触头是一个棒或一个金属块，典型地是由钛，铝或硬化钢制成，尺寸定为可使其驻留于施加的频率。触头与工件接触，将机械振动传给工件。一夹具或槽形件支撑两个需要焊接的零件，并使该两个零件对正。该夹具通常用铝或钢制成，并且有时还衬以浇铸的氨基甲酸乙酯或其它弹性材料。
适当的连接结构对获得理想焊接效果是必需的。诸如材料类型，零件几何形状和焊接接合部的要求等因素都是决定结构时需要加以考虑的。接合部应具有小而均匀的初始接触面积和某些对正的结构要素，以集中超声波能量，迅速局部扩散能量。一种最普遍采用的能量导向结构是由待焊接的零件表面的小三角形焊珠构成的。在一种类型的焊接中，采用了一种尖锐的或抵触的接合部，以获得高强度气密封接。焊接过程中，接合部被熔化并嵌在一起，产生一种揉合式焊接。
多种热塑性聚合物都可焊接。非结晶树脂例如聚苯乙烯，丙烯腈丁二烯苯乙烯共聚物（ABS），聚碳酸酯等具有非常好的能量效果，一般都可用于超声波焊接。它们的特征是具有无规则的分子排列和宽的软化温度范围。这使材料易于流动，而不致过早固化。具有较高结晶性等级的树脂，由于它们的高有序分子结构，要求较高的超声波能量等级。某些不同的树脂，如果它们的玻璃转变温度相同（典型地在约40F内），也可焊接。并且这些树脂还有某种相近的分子结构。其典型例子是ABS与聚丙烯树脂，聚碳酸酯与聚丙烯树脂，以及聚苯乙烯与聚苯撑氧。
许多其它因素，例如湿度，填充物和脱模剂等也对超声波焊接热塑性塑料的能力产生影响。理想的焊接特别要求焊前对塑料零件进行干燥。并已知道，填充物的填充量超过30-35%时，会阻碍超声波焊接。高于这些量，由于接合区所含可熔性材料不足，不能保证高强度焊接。此外，填充物，例如玻璃和矿物质，还可成为磨料，引起触头以高于35%的等级过量磨损。脱模剂减小了材料的摩擦系数，但也会对焊接带来不利影响。因此焊接表面应于焊接前用适当的清洁物进行清洁，去除任何表面污物。
超声波焊接技术的普通知识经常提示，需焊接的接合部应彻底经过清洁，而没有上述物质。因此，焊接带金属镀层塑料件既困难又费钱。焊接接合部的金属镀层必须去除以保证正确焊接。这就要求那些例如用作屏蔽型射频（RF）罩壳的带镀层的塑料件在镀金属时须有选择地作遮盖处理，或在焊接前去除镀层。显然，能对整件带镀层的塑料件进行焊接，将是对该技术领域作出的有益改进。
概括地说，本发明提供了一种超声波焊接两个塑料零件的方法，一个塑料零件的焊接接合部覆盖有金属层，另一个塑料零件具有互补的焊接接合部，通过将上述两个焊接接合部用超声波彼此焊接，将两个零件连为一体。
在本发明的一种实施例中，在连接步骤之前，在第一和第二塑料零件上施加了一个力，该力显著大于使两个焊接接合件相互接触所需的力。
在本发明的另一个实施例中，一种用超声波焊接的镀金属的塑料组件包括两个塑料零件，每一零件具有一焊接接合部，至少一个焊接接合部焊前覆盖有一金属层，两焊接接合部的每一部分都发生变形，以在两个焊接接合部间形成焊接连接。
图1是本发明的超声波焊接示意图；
图2是按照本发明的方法焊接后的两个金属化塑料零件的剖视图；
图3说明用来确定焊接效果的试验方法。
尽管各权利要求限定了体现本发明新颖性的特征，但通过以下结合附图的详细说明，相信可以对本发明更清楚地理解，图中各序号见下面的说明。
参见图1，超声波焊接通常是这样进行的：60HZ交流电流（AC）线路的能量被转换成高（超声波）频率（20-40KHZ）AC能量，进而通过压电换能器转化为具有同一超声频率的机械振动。上述能量转换在通常称为发生器/转换器10的超声波焊机部分进行。机械振动12通过助推器15和焊接触头20传至需连接的塑料零件25，30。该组件总称“叠件”（stack）。助推器15和触头20的几何形状确定叠件中出现的振动放大程度，因而确定了施加在塑料零件25，30上的振动22。振幅在很大程度上决定了可利用的超声波能量。焊接触头20按常规设计成能与第一塑料件25配合，第二塑料件被一常规结构的夹具35夹持，该夹具还起防止其变形的作用。机械振动22引起分子间的振动，从而在塑料件25，30中产生摩擦热。通过适当的焊接接合部设计，可使分子间的摩擦在局部最大限度增强，从而有选择地熔化局部塑料零件，将它们焊在一起。整个过程是在施加的机械力40作用下进行的，该力的方向使第一塑料零件25与第二塑料零件30接触，从而保证它们紧密接触。该力分两步施加，第一步在施加超声波振动22之前，称为触发力，第二步在施加超声波振动过程中，称为焊接力。触发力显著大于使两焊接接合部彼此接触所需的力，以保证沿整个焊接接合面同时发生熔化，一旦施加该触发力，立即开始引入超声波能量。焊接力不必等于触发力，但在很大程度上决定了两零件连接的速率。
在本发明的一种实施例中，第一和第二塑料件25，30由注塑试件构成，这种试件被称为改型工字梁，它们明显不同于美国焊接学会塑料和复合材料连接G-1分会（The American welding society G-1 subcommitee on the Joining of plastics and Composites）制定的标准试件之处在于，它们在至少一个塑料件的至少一个区域有尖锐部分23。该第一和第二塑料件用聚碳酸酯（一种热塑性塑料）注塑而成，然后通过化学镀敷工艺覆盖一层铜或镍镀层27。测得的铜镀层厚约1μm。测得的镍镀层厚约0.25μm。它发现金属镀层厚度范围从0.1μm至5μm是有用的，精确的厚度随结构要求和所选择的金属而变化。然而镀层不能形成得太厚或太坚固，以致不能被焊接力克服，导致不能实现良好焊接。其它等同的镀敷塑料件的方法也可成功地使用，例如真空沉积镀层（阴极真空喷镀，蒸发沉积镀，等），电镀，火焰喷镀，用镀金属涂料刷镀等。此外，其它金属，如铝，铬，锡或钛，也可使用。与传统技术不同之处在于，金属镀层27形成在整个零件表面，并且不被有选择地去除，或在镀敷时对焊接接合部进行罩护。焊前第一塑料件25如图示那样相对第二塑料件定位。采用适当的夹具35，使两塑料件的互补焊接接合部正确对正。在这个实施例示意图中，第二塑料件30包含一带尖锐部分23的焊接接合部。两焊接接合部的形状还可在两塑料零件间互换。尖锐部分23已被发现对焊接过程中在金属镀层中形成一薄弱点是有用的。这个薄弱点通过允许塑料更容易流动和对另一塑料件形成坚固焊接连接有利于焊接工艺。
施加在第一塑料件上的触发力为245N，振幅为60μm，而焊接力为267N。终止超声波能量后，（两零件在施加的选定焊接力作用下保持一起的时间为0.5秒。采用的这些工艺条件使两塑料件中的互补焊接接合部局部加热至超过聚碳酸酯的熔点。熔化的塑料发生变形，然后在中断超声波能量后再固化为焊接连接部。参见图2，焊后金属镀层27破碎，弥散于整个焊接连接部，允许两塑料件流成一体。一旦完成，该工艺便可提供一种焊成的镀金属塑料组件。
参见图3，镀金属塑料组件38放在一Instron万能试验机上的夹具中，并施以如图所示的力50，51。该作用力不断增大，直至使两焊接件最终拉开造成破坏为止。该试验按美国焊接学会塑料和复合件连接G-1分会制订的标准试验规程进行。简单地说，该试验规程就是确定使标准焊接试件造成破坏所需的力，与造成具有相同几何形状的模塑单件试件（对照试件）破坏所需的力进行比较。用各种塑料件进行的试验结果如下：
材料  平均强度
单体模塑聚碳酸酯对照件  6352N
焊接的无镀层聚碳酸酯试件  6325N
焊接的有镀层聚碳酸酯试件  6280N
上述结果显示，镀金属的塑料组件可用超声波焊接连接两个镀金属的塑料件成功地制成。用两个在焊接区全部镀有金属的塑料件可以获得相当无镀层塑料件的焊接效果。尽管已对本发明的优选实施例作了说明和描述，但显然本发明并不受其限制。例如，可采用不同的触发力、金属镀层、塑料成份和焊接接头形状。本发明各种变型、变换，变化，代替和等同替换对该领域的技术人员来说都是显见的，均在权利要求限定的本发明保护范围之内。

Claims (14)

1、一种超声波焊接方法，它包括如下步骤：
提供第一和第二塑料件，第一塑料件的焊接接合部覆盖有金属层，而第二塑料件具有互补的焊接接合部；以及
用超声波将两焊接接合部相互焊接，将第一和第二塑料件连成一体。
2、如权利要求1所述的方法，其中第一塑料件的焊接接合部具有尖锐部分。
3、如权利要求1所述的方法，其中第二塑料件具有覆盖所述互补的焊接接合部的金属层。
4、如权利要求3所述的方法，其中第二塑料件的焊接接合部具有尖锐部分。
5、如权利要求1所述的方法，它还包括在所述连接步骤前在第一和第二塑料件上施力的步骤。
6、一种超声波焊接方法，它包括如下步骤：
提供第一和第二塑料件，第一塑料件的焊接接合部覆盖有金属层，而第二塑料件具有互补的焊接接合部；
将第一塑料件的焊接接合部与第二塑料件的互补焊接接合部对正；
在第一和第二塑料件上施加一显著大于使两焊接接合部彼此接触所需力的力；以及
用超声波将两焊接接合部相互焊接，将第一和第二塑料件连成一体。
7、如权利要求6所述的方法，其中第一塑料件的焊接接合部有尖锐部分。
8、如权利要求6所述的方法，其中第二塑料件具有覆盖所述互补焊接接合部的金属层。
9、如权利要求8所述的方法，其中第二塑料件的焊接接合部具有尖锐部分。
10、一种超声波焊接的镀有金属的塑料组件，它包括：
两个塑料件，每一件具有一焊接接合部，至少一个焊接接合部焊接前覆盖有金属层；以及
两焊接接合部的每一部分都发生变形，以形成两焊接接合部间的焊接连接。
11、如权利要求10所述的超声波焊接的镀有金属的塑料组件，其中一个塑料件的焊接接合部具有尖锐部分。
12、如权利要求10所述的超声波焊接的镀有金属的塑料组件，其中所述的两个焊接接合部焊接前都覆盖有金属层。
13、如权利要求10所述的超声波焊接的镀有金属的塑料组件，其中所述的两个焊接接合部都具有尖锐部分。
14、如权利要求10所述的超声波焊接的镀有金属的塑料组件，在焊接连接区还包括一金属层。
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CN1914026B (zh) * 2004-02-03 2011-06-29 日本发条株式会社 超声波焊接构造及超声波焊接方法
CN101817232A (zh) * 2010-05-21 2010-09-01 哈尔滨东安发动机（集团）有限公司 塑料零件的焊接方法
CN101817232B (zh) * 2010-05-21 2016-08-03 哈尔滨东安发动机（集团）有限公司 塑料零件的焊接方法
CN108330433A (zh) * 2018-01-31 2018-07-27 厦门建霖健康家居股份有限公司 一种塑料电镀工件的环保焊接方法
CN113085194A (zh) * 2021-03-11 2021-07-09 卓外（上海）医疗电子科技有限公司 一种适用于内窥镜结构的异质接合方法
CN113954372A (zh) * 2021-09-28 2022-01-21 惠州市壹品科技有限公司 超声波焊接处理方法以及超声波焊接预热组件

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KR0166138B1 (ko) 1999-03-20
EP0685318A3 (en) 1998-03-11
KR950031469A (ko) 1995-12-18
CN1050565C (zh) 2000-03-22
DE69528314T2 (de) 2003-01-23
US5397408A (en) 1995-03-14
DE69528314D1 (de) 2002-10-31
EP0685318B1 (en) 2002-09-25
EP0685318A2 (en) 1995-12-06

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