CN111433006B - 传导焊接 - Google Patents

传导焊接 Download PDF

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Publication number
CN111433006B
CN111433006B CN201880059749.XA CN201880059749A CN111433006B CN 111433006 B CN111433006 B CN 111433006B CN 201880059749 A CN201880059749 A CN 201880059749A CN 111433006 B CN111433006 B CN 111433006B
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China
Prior art keywords
heat sink
heat
welding apparatus
elongate
strip
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CN201880059749.XA
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English (en)
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CN111433006A (zh
Inventor
亚普·威廉·范英根
马尔科·多尔德苏姆
约翰·特尼森
安特·奥弗林加
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GKN Fokker Aerospace BV
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Fokker Aerostructures BV
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Publication of CN111433006A publication Critical patent/CN111433006A/zh
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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
    • 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
    • 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
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated 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
    • 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
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/22—Heated wire resistive ribbon, resistive band or resistive strip
    • 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
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/22—Heated wire resistive ribbon, resistive band or resistive strip
    • B29C65/221—Heated wire resistive ribbon, resistive band or resistive strip characterised by the type of heated wire, resistive ribbon, band or strip
    • B29C65/224—Heated wire resistive ribbon, resistive band or resistive strip characterised by the type of heated wire, resistive ribbon, band or strip being a resistive ribbon, a resistive band or a resistive strip
    • 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
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/24—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools characterised by the means for heating the tool
    • B29C65/30—Electrical means
    • B29C65/32—Induction
    • 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
    • B29C66/1122—Single lap to lap joints, i.e. overlap 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
    • B29C66/301—Three-dimensional joints, i.e. the joined area being substantially non-flat
    • 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
    • B29C66/347—General aspects dealing with the joint area or with the area to be joined using particular temperature distributions or gradients; using particular heat distributions or gradients
    • B29C66/3472—General aspects dealing with the joint area or with the area to be joined using particular temperature distributions or gradients; using particular heat distributions or gradients in the plane of the joint, e.g. along the joint line in the plane of the joint or perpendicular to the joint line in the plane of the joint
    • 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
    • B29C66/348—Avoiding melting or weakening of the zone directly next to the joint area, e.g. by cooling
    • 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
    • B29C66/349—Cooling the welding zone on the welding spot
    • B29C66/3494—Cooling the welding zone on the welding spot while keeping the welding zone under 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
    • 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
    • B29C66/50—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
    • B29C66/71—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
    • B29C66/72—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
    • 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
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
    • B29C66/72141—Fibres of continuous length
    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8145—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81451—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps being adaptable to the surface of the joint
    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8145—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81455—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps being a fluid inflatable bag or bladder, a diaphragm or a vacuum bag for applying isostatic 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8145—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81457—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps comprising a block or layer of deformable material, e.g. sponge, foam, rubber
    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8145—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81461—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps being multi-lamellar or segmented, i.e. comprising a plurality of strips, plates or stacked elements
    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/818—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps
    • B29C66/8182—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the thermal insulating constructional aspects
    • B29C66/81821—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the thermal insulating constructional aspects of the welding jaws
    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/818—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps
    • B29C66/8183—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the thermal conducting constructional aspects
    • B29C66/81831—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the thermal conducting constructional aspects of the welding jaws
    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/818—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps
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Abstract

本发明涉及用于纤维增强树脂基材料的焊接设备，焊接设备包括伸长柔性导热条和绕导热条的周边的至少一部分延伸的伸长散热器。伸长散热器被划分成多个段，其中相邻段能够相对于彼此移动。

Description

传导焊接
技术领域
本发明涉及用于将复合物层压件连接在一起特别是焊接在一起的改进焊接设备和方法。
背景技术
复合物层压件现在广泛地用于汽车和航空航天行业，从而以最小的重量提供坚固的结构。诸如面板和增强肋(或类似物)之类的复合物结构能够以许多不同的方式联接在一起，包括诸如铆钉或螺母和螺栓的常规联接件。
已经发展出替选方法，这些方法有利地省去了对这些类型的联接件的需要，并且涉及将复合物构件直接焊接在一起。这些焊接技术涉及将层压件材料的多个部分加热到复合物中的树脂开始软化和熔化的温度。然后在一时间段内施加压力，使各个构件中的树脂熔融在一起。热和压力的去除允许构件冷却并且允许树脂重新凝固，从而将两个(或更多个)构件紧固在一起。
在许多应用中，简单的焊接过程足以满足给定应用的要求。然而，在具有严格安全要求的应用中，常规焊接技术变得不可靠。具体地，常规技术能够导致不均匀焊接，这些不均匀焊接可能包含分层(复合物结构内的层的分离)或空隙。这些缺陷可能在构件的表面上不可见，也可能以焊接区域上或焊接区域周围的扭曲形式出现。
内部和表面缺陷在诸如航空航天行业等应用中特别令人关注，在航空航天行业中，复合物构件形成了飞机的结构或空气动力学构件。由于这些缺陷，航空航天行业中的严格要求因此限制了层压件焊接的使用。
本发明人已经设计了一种非常规的焊接方法和设备，其允许将复合物构件可靠地焊接在一起。该技术和方法还允许焊接复杂的几何形状，并且还能够适应局部厚度变化和浅斜面。由此能够实现无空隙和无分层的焊接，这在航空航天(和其它)应用中，就焊接的美观性和结构完整性这两者而言都是非常期望的。在航空航天行业中，由碳纤维构件形成的主要结构尤其如此。
发明内容
本发明的各个方面在所附权利要求中提出。
从第一方面看，提供一种焊接设备，所述焊接设备用于纤维增强热塑性树脂基材料，所述焊接设备包括伸长柔性导热条和伸长散热器，所述伸长散热器绕所述导热条的周边的至少一部分延伸，其中所述伸长散热器被划分成多个段，其中相邻段能够相对于彼此移动。
因而，根据本文所述的发明，代替采用刚性体进行传导加热的常规方法，使用改进的且柔性的带。如果被适当地加压，则柔性带能够遵循局部厚度变化，甚至是浅斜面，并且因此能够产生均匀的焊接压力，从而产生无空隙的焊接。
有利地，在焊接区域旁边施加散热器以将热从层压件中吸出。由于散热器，被加压区域外部的层压件保持低于熔融温度。这样避免了分层，因此不会出现空隙。
与常规焊接技术相比，本发明提供了许多令人惊讶的技术和商业优势。例如，热塑性部件的焊接能够大大减少紧固件的数目，这能够减少所结合的构件的重量，还能够节省多达30％的组装成本。
此外，本文所述的焊接方法还提供了其它技术优势，包括：
·使用柔性经加热的工具对热塑性复合物部件进行牢固焊接，能够适应典型的部件厚度公差和较小的间隙；
·也能够对覆盖有金属防雷网的碳复合物层压件进行牢固焊接；
·使用小型焊接工具进行焊接，小型焊接工具能够在狭窄空间中进行焊接，并且能够作为端执行器安装在机器人上；
·从一侧进行加热和加压，这意味着OML表面能够保持光滑与精确(OML侧上的刚性工具)。
如上所述，提供与柔性导热条结合的柔性散热器的反直觉方法允许在焊接工具中适应轮廓和制造的不一致性。这确保了在焊接过程期间热在整个构件上均匀地传导，防止形成不均匀的焊接，即可能包含分层、空隙或其它不良效果的焊接。
伸长柔性导热条可以是任何合适的材料，其能够传递必要的温度以熔化所选择的待焊接材料中的树脂。例如，伸长柔性导热条可以是伸长金属条，诸如殷钢、不锈钢或另一合适的高温材料。
类似地，散热器可以由任何合适的材料形成，并且具有将热从层压件传走的功能，即与导热条的目的相反。
散热器通常呈“U”形截面的形式，具有背衬部和从背衬部伸出的两个侧部。这在散热器的中间产生了空隙，能够将导热条和加热装置(下面讨论)定位在该空隙中。
柔性，即散热器沿着其长度偏转成曲线的能力(参见图3)可以通过将散热器部分地或完全地切片来实现。因而，可以穿过背衬部并沿着侧部形成狭槽。以这种方式对散热器切片产生了一系列段。如果然后将散热器加载到弯曲表面上，则这些段能够根据变形是凹形变形还是凸形变形而改变角度。通过将切片或狭槽限制为每一个侧部长度的部分长度，能够将散热器作为单个构件保持在一起。
在偏转时，相邻的段根据层压件表面上的变形的曲率半径相对于彼此偏转。
在包括狭槽的散热器布置中，每一个狭槽通常都可以用于适应部件表面的自然厚度变化。因而，所需的变形非常小，因此狭槽的最小宽度仅受工具制造要求的限制。
替代地，可以在散热器的整个深度上形成狭槽或切片，从而形成多个独立段。作为单独的段，相邻段根据层压件表面的变形相对于彼此上下移动。
在具有完全切片的散热器与完全切片的柔性导热条相结合的这种布置中(下面将详细讨论的图9和图10)，能够有利地适应更大的厚度变化，诸如蒙皮中的斜面。
有利地，每一个段都可以与相邻段电绝缘。因而，在将感应线圈用作加热元件的布置中，能够防止在每一个段中产生涡电流。
散热器的每一个侧部都被布置成沿着远侧边缘(从U形的基部开始测量)接触层压件表面。这形成了连续表面，该连续表面能够沿着伸长导热条的边缘或周边(特别是导热条的长边)与层压件形成接触。实际上，导热条沿着其最长边缘被夹在散热器的两个边缘之间。
这些边缘能够在焊接过程期间从层压件收集热，并有利地紧邻焊接区域外部将热从层压件吸走。这防止了热侧向传播。
为了将导热条定位在U形的远侧端内，同时维持与散热器的集热边缘的接触，可以通过将导热条安置在散热器的开口端内的方式使散热器成阶梯状。
有利地，阶梯状轮廓使得柔性导热条的一部分延伸超过集热边缘的最远侧部分。因而，在焊接过程期间，导热条首先与层压件形成接触，并开始软化树脂。然后，在散热器边缘与层压件的表面邻接并收集热之前，导热条穿透表面达预定深度。
最佳深度值将取决于特定的布置和要制造的部件。在一个示例中，可以使用0.1+/-0.1mm的目标，以应对工具制造公差并防止导热条位于散热器下方。
散热器内的空隙可以设有任何合适的热源，该热源能够将热传递给伸长柔性(且导热)条。例如，电感应线圈可以沿着设备的长度延伸。有利地，线圈能够方便地遵循由层压件的表面轮廓引起的变形。
电阻加热棒作为热源也可以与本发明结合使用。
为了防止电流流入散热器和/或导热条中，线圈可以被一个或更多个电绝缘体包围。例如，可以设置一对绝缘体，其中电导体的第一侧面对伸长柔性导热条，而电导体的相反侧面对散热器内的空隙。
伸长散热器、伸长柔性导热条、电导体和电绝缘体可以方便地容纳在形成在焊接设备的外壳中的盲凹部中。如下所述，盲凹部提供：
-用于设备的子构件的外壳；
-限制(即控制)散热器的段运动的装置；
-能够在其上产生焊接压力的表面；
-通过被动或主动冷却装置从散热器收集热的本体。
焊接压力被施加到散热器的背衬部，背衬部继而经由上述阶梯状部分向柔性导热条施加载荷。因而，导热条和散热器使用预定压力与层压件表面形成接触。这种力能够以多种方式施加，例如使用致动器、凸轮等。
然而，发明人已经确定，施加进行焊接所需的载荷的便利手段是将可充气软管或气囊结合到盲凹部中并将其定位在散热器的后方。因而，在充气时，该软管膨胀并向散热器施加力，从而将散热器(以及柔性条)推向层压件表面。
为了保护柔性软管免受由散热器收集的热的影响，可以在散热器和软管之间有利地引入绝热层。
为了监控焊接中的实际温度，可以使用一个或更多个合适的热电偶。例如，可以在焊接未加热侧使用小型非接触式高温计监控材料中的热。使用温度传感器可以有利地保证已经达到预定的焊缝温度。
另外，这还可以防止“吻接”，即在太低的温度下形成，因此强度不足的焊接。这些有缺陷的焊接并非总是能够通过无损检测(NDT)技术检测到的。
从另一方面来看，提供一种将第一热塑性基构件焊接到第二纤维增强树脂基构件的方法，焊接设备包括伸长柔性导热条和伸长散热器，所述伸长散热器绕所述导热条的周边的至少一部分延伸，其中所述伸长散热器被划分成多个段，其中相邻段能够相对于彼此移动，所述方法包括使所述焊接设备与第一纤维增强树脂基构件形成接触并且施加力的步骤，使得所述散热器和柔性导热条变形，使得所述条及所述散热器与所述第一构件的表面轮廓匹配。
工具会保留在产品上，直到焊接冷却至200℃以下。这产生了本文参考图11所述的冷却曲线。已经确定的是，如果冷却速度太快，则例如为了树脂中足够的结晶度，能够通过加热装置设定点的受控下降引入较慢的冷却速度。
从又进一步方面来看，提供一种用于热塑性基材料的焊接设备，所述焊接设备包括柔性伸长导热条和相关联的散热器，所述散热器从所述伸长条的最长边缘侧向延伸，其中所述散热器能够沿所述条的长度变形，以便在使用中与待焊接的热塑性基材料中的变形匹配。
从又另一方面来看，提供一种用于热塑性基材料的焊接设备，所述焊接设备包括柔性伸长导热条和相关联的热源，所述热源被布置成在第一方向上将热引导至待焊接的层压件表面；和散热器，所述散热器从所述伸长条的最长边缘侧向延伸，并被布置成从所述层压件表面收集热并将热在第二相反方向上传递，其中所述散热器能够沿所述条的长度变形，以便在使用中与待焊接的热塑性基材料中的变形匹配。
从又进一步方面来看，可以借助于机械人臂或梁来应用一种焊接设备和方法，以提供计算机控制焊接过程。
附图说明
现在将参考附图仅以示例的方式描述本发明的各个方面，其中：
图1A和图1B示出了两个层压件以及层压件表面几何形状之间的变化；
图2A、图2B和图2C示出了常规的层压件焊接布置(图2A)以及根据本发明的改进焊接布置(图2B和图2C)；
图3示出了散热器、导热条和层压件的放大且夸大截面图；
图4示出了穿过图2B和图2C中所示的散热器的截面图；
图5A和图5B示出了在常规焊接过程中(图5A)和本技术(图5B)中的焊接期间的热流动路径；
图6示出了穿过根据本文所述的发明的焊接设备的截面图；
图7示出了图6中所示的焊接设备的轴测分解图；
图8示出了处于其中能够发生焊接的阶段的焊接设备；
图9示出了具有细分散热器和细分导热条的替代实施例；
图10示出了图9中所示的焊接设备的分解轴测图；
图11示出了UD PEKK材料的时间与温度关系的焊接曲线图的示例。
虽然本发明易于存在各种变型和替代形式，但是在附图中通过示例的方式示出了具体的实施例，并且在本文中对其进行了详细描述。然而，应理解的是，附图和所附的详细描述并非旨在将本发明限制为所公开的特定形式，相反，本发明将覆盖落入所要求保护的发明的精神和范围内的所有变型、等同物和替代物。
应认识到，本文描述的本发明的各个方面的特征能够以任何合适的组合方便且可互换地使用。还应认识到，本发明不仅涵盖单个实施例，而且涵盖本文已经讨论的实施例的组合。
具体实施方式
图1A和图1B示出了两个层压件以及层压件表面几何形状之间的变化。首先参考图1B，其中示出了将被结合(焊接)在一起的两个层压件(L1、L2)。
在该示例中，层压件由包含在热塑性树脂中的碳纤维形成。这些材料通常被称为碳纤维增强热塑性塑料(CFRP)。应认识到，本文所述的设备和方法同样可以应用于使用树脂材料夹带纤维的其它材料。
图1B示出了用于将两个层压件(L1、L2)焊接在一起的常规布置。这个简单的过程包括在上下砧(AV1、AV2)之间布置两个层压件。加热其中一个砧，并使两个砧朝向彼此偏压以产生焊接压力。热通过砧传导到层压件，并使层压件内的树脂熔化。偏压力使树脂融合在一起。然后释放砧，使其冷却，树脂重新硬化或凝固，从而形成焊缝。
诸如此类的常规焊接布置使得复合物层压件能够容易且方便地结合(焊接)在一起。
然而，参考图1A，能够看出层压件并不总是完全均匀和平坦的。这是其中形成层压件的方式的结果，即形成多个单层，然后将这些单层固化在一起。该制造过程的结果是表面轮廓的变化，从而导致出现空间或空腔，如图1A中所示。通常，能够通过增加图1B中的砧之间的偏压压力或力和/或增加焊接的温度或持续时间来应对这些空腔。因而能够去除这些空腔。
然而，尽管这能够解决图1A所示的问题，但发明人已经确定，它对焊缝以及围绕焊缝的构件区域造成其它有害影响。
参考图2A，能够看到传统的加热器H1，其被朝向相对的砧AV2偏压或推动，从而使层压件L1和L2被压在一起。启动加热器，并形成树脂WP的焊接熔池，该焊接熔池延伸穿过两个层压件L1和L2。然而，由于施加热梯度和焊接压力的组合以产生焊缝，在焊缝P1的周边处可能发生分层。
如果将层压件加热到高于熔融温度而没有足够的压力，则会发生分层。这是由于在层压件的制造期间继承的层压件中的预拉伸或压缩形式，层压件制造本身通常在高压下进行。此外，如果加热到高于熔融温度而没有施加适当的压力，则树脂中的除气会产生空隙。
当停用加热并去除焊接力(冷却至200℃以下之后)时，焊接熔池内的树脂将重新凝固，并且所述两个层压件被沿着焊接线焊接在一起，即当停用加热时，焊接熔池内的树脂会冷却并重新凝固，并且所述两个层压件被沿着焊接线焊接在一起。在冷却至200℃以下之后，去除焊接力。然而，如上所述，围绕并沿着焊缝延伸的区域可能遭受材料内的分层和其它不连续性的影响。这样的不连续性可能不利于构件和焊接的结构完整性，如上所述，这对于主要航空航天构件而言尤其关切。
参考本发明，图2B示出了改进的焊接设备1。
焊接工具或设备1包括柔性且伸长的金属(或其它导热)条2，该金属导热条2相对于焊接线位于工具的中心。导热条2相对较薄，使得导热条2能够沿着其长度屈曲(图2中未示出)。如图所示，导热条2能够与第一层压件层3形成接触，第一层压件层3本身紧靠第二层4定位，使得如下文所述，该第一层压件层3和第二层4能够在启用工具时被结合在一起，即焊接在一起。
该工具包括被布置成围绕导热条的散热器5。散热器5呈水平的上部6和两个侧部7a、7a的形式，该上部6和所述两个侧部7a、7a限定了U形的截面，并在散热器内形成空腔或空间8，并在下端被导热条2封闭。
散热器的每一个侧部7a、7b都以如图2B中所示的阶梯状方式与导热条2协作。具体地，每一个侧部7a、7b都包括与导热条的上表面接合的第一部分和向下延伸到导热条的侧面并足够长以与第一层压件3接触的区段部分。实际上，导热条2位于或被容纳在散热器7内。
导热条2和散热器5限定了工具9A的第一部分9A，工具9A在层压件3、4的第一侧(在图2B中为上侧)上操作。工具9B的相对部分被布置在层压件3、4的相反侧上，并提供能够对其施加焊接力的表面。例如，工具9B可以是桌子，工具9A可以是安装在机械臂上的可动头。
图2C以散热器的轴测图、截面图以及侧立面图单独地示出了散热器。图2C示出了沿z方向延伸的散热器的长度。如图所示，散热器包括多个狭缝或狭槽10，这些狭缝或狭槽10从上表面6朝向侧部的接近接收导热条的空间(图2C中未示出)的端部延伸。狭缝或狭槽10将散热器分成多个段11。所有段11都在散热器5的底部处连接在一起，狭缝或狭槽终止在散热器5的底部处。实际上，散热器的在每一个侧部7a、7b的端部处的一部分形成根部，该根部将这些段连接在一起。每一个段11都具有如图2B中所示的截面。
图2C还示出了散热器的侧立面图，其示出了狭缝的均匀间距。然而，狭缝的精确间距(以及段的尺寸)取决于所需的焊接特性。
图2C进一步示出了散热器的侧部的远侧端的阶梯状轮廓，其中较长的部分布置(在使用中)成接触待焊接的层压件，这将参考图4更详细地描述。
图3示出了散热器5、导热条2和层压件3的放大且夸大截面图。该截面在导热条和层压件的曲率方面被夸大，以更清楚地示出段11之间的狭缝11’是如何使散热器适应不平坦或起伏的表面。
如区域A中所示，散热器被布置在下层层压件的凸形轮廓上。这里，允许这些段以扇形散开或展开，而狭缝11’远离根部变得更大。相反，在区域B中，散热器被布置在下层层压件的凹形轮廓上。这里，允许段闭合在一起，而狭缝11’远离根部变小。应明白的是，狭缝由此使散热器适应层压件表面轮廓中的变化，同时保持与导热条2和层压件3的接触。
图3是散热器、导热条和层压件的分解图。应认识到的是，在使用中，散热器和柔性导热条2被联接在一起(如参考图2B所述的)，然后使它们与层压件表面3形成接触。如图所示，散热器和导热条两者的柔性使它们与层压件的轮廓(放大)匹配。
图4更详细地示出了图2B的散热器、导热条和绝缘体。如图所示，散热器5包括朝向柔性导热条2延伸的两个侧部7a、7b。侧部7a、7b的端部包括如图4中所示被构造成接收导热条的轮廓的阶梯状截面。
应认识到，阶梯状轮廓可以是与导热条互补的任何几何形状，并且该阶梯状轮廓能够与导热条的一部分接合，以便将焊接载荷转移到导热条上，并且因此转移到层压件上。
散热器5和导热条2由位于导热条和散热器之间的绝热层12隔开。这防止了热从导热条2进入到散热器本身中(然后散热器本身将被加热)。
可以选择任何合适的材料。合适的示例包括玻璃织物、耐高温涂层或诸如陶瓷等的分离材料。散热器本身也可以是任何合适的材料，诸如铝或不锈钢等。柔性导热条同样可以选自任何合适的材料，例如钢、殷钢或不锈钢。更具体地并有利地，该材料必须耐热至少500℃。
返回图4，侧部7a、7b的端部的阶梯状截面还包括沿着散热器一直延伸的远侧边缘13(如图2C中所示)。如图4中所示，远侧边缘13被有利地布置成其不延伸超过导热条2的最下表面。导热条2的最下表面延伸超过边缘13的最下表面一段距离Sd。
在使用中，导热条2(如下面进一步讨论的那样被加热)在散热器5的边缘13之前与层压件表面接触。这允许导热条加热层压件，而不使散热器减慢加热过程。施加到顶表面6上的焊接压力使导热条2穿透层压件表面，直到边缘13与层压件表面形成接触。
一旦在边缘13和层压件的上表面之间形成接触，散热器便开始从层压件吸收热，并通过侧部7a、7b将热传递到散热器的主体和根部。参考图5对此进行进一步描述。
返回图4，该设备的传热特性能够根据深度距离Sd以及HSw和Sw的比率(即边缘部分13和导热条2的面积比率)来选择。
参考图5A和图5B能够看出本工具布置的有利热效应。
图5A示出了常规的层压件焊接方法，其中将被加热的部分14施加到层压件3。如箭头X所示，热从焊接区域向外传导并加热层压件的周围区域。这种加热不仅可能导致分层(如上所述)，而且还可能导致表面不规则，如图5A中紧邻被加热的部分14的凸形部分所示的。
相反，在图5B(其是根据本发明的焊接设备)中能够看到不同的热分布。如图所示，导热条2通过绝缘体12与散热器5绝缘。导热条通过焊接压力P与层压件3形成接触。散热器的边缘部分13现在与紧邻焊接区域的层压件表面接触，并且如图所示，焊接区域Y被限制在导热条2之下。这里，防止了多余的热水平散发，而是由散热器收集并引出层压件(如箭头H所示)。这防止了焊接区域周围的层压件的分层以及损坏。
因而，单就本焊接设备的散热器方面来说就已经提供了一种改进的层压件焊接技术。
现在将参考图6至X描述工具的其它协同方面。
图6示出了包含上述柔性散热器布置的焊接设备的截面图。在图6中，增强肋3被附接到水平的层压件表面4。在图6的截面中示出了与上面讨论的构件相同的构件，即柔性导热条2、绝缘层12和散热器5。现在将描述焊接工具的其余部分。
如上所述，柔性导热条2将热传递到层压件以进行焊接。热通过电驱动的加热元件提供，在图6中所示的实施例中，该加热元件位于在柔性导热条2的顶部中形成的凹形凹部中。然后，绝缘体被定位在电加热元件的顶部上，因此该元件的下半部被导热条2的凹形凹部包围，而上半部被上部绝缘体16的凹形凹部包围。上部绝缘体将散热器与由电加热器产生的热隔离。因而，加热器15、绝缘体16和柔性导热条被包含在形成于散热器的中心区域内的空间内。
有利地，电加热元件15和上部绝缘体16也可以是柔性的，使得它们能够与导热条2和散热器5一起屈曲，以适应如上参考图3所讨论的层压件表面轮廓的变化。
能够看到散热器5正上方的柔性橡胶条17，该柔性橡胶条17被定位于散热器5和可充气橡胶软管或气囊18之间。这些构件都位于工具上部外壳20的空隙19内。
可充气软管连接到气体或空气源(未示出)，并且能够在空隙19内选择性地充气到预定压力。充气使气囊膨胀并向橡胶条17的上表面施加力。这继而向散热器5的上表面6施加力，该散热器本身联接至柔性导热条。因而，能够看出，对软管18充气能够选择性地将焊接力施加到散热器和柔性导热条2。
可以根据具体构造选择软管中的压力。有利地，为了施加合适的焊接压力，软管中的压力可以在6巴+/-1巴的范围内。
参考图6，其中示出了焊接工具外壳，焊接工具外壳中包含上述布置。该外壳包括上部外壳20，该上部外壳20包含软管18、橡胶条17、散热器5、绝缘体16、电加热器15和柔性导热条2。与上部外壳相对的是第二下部外壳21，第二下部外壳21用作能够对其施加焊接压力/力的表面。下部外壳包括耐热且绝缘的表面22，在焊接过程中，层压件4与该绝缘表面接触。
下部外壳21可以是砧的下半部的形式，该砧的下半部联接到上部外壳，从而允许两者被合在一起或分开，由此允许层压件位于外壳之间以进行焊接。
在另一种布置中，下部外壳可以是固定床或夹具的形式，并且其中上部外壳能够相对于下部外壳移动。如果下部外壳/夹具能够将层压件支撑在焊接位置处，则各种布置都是可能的。例如，上部外壳可以位于机械臂上，而下部外壳是固定的。然后可以在不同位置进行多次焊接。
在操作中，焊接过程包括下列步骤：
(a)将层压件3、4相对于上部和下部外壳放置在适当位置；
(b)将软管18加压，使散热片和柔性导热条被压到上部层压件上，下部外壳与下部层压件接触，并使两者形成紧密接触。柔性导热条和散热器的变形适应表面轮廓的变化；
(c)对铜线圈15施加交流感应电流，以加热金属条2；
(d)产生的热通过传导传递给热塑性复合物部件3和4；
(e)在被加热的导热条2旁边，散热器5从在期望区域中包含热的热塑性复合物部件吸收热，并且防止金属条沉入热塑性复合物部件中太深；
(f)在预定时间段之后，使电磁感应线圈停用，层压件内的树脂固化，从而使两个层压件结合(即焊接)在一起；
(g)释放软管压力，并且使上部和下部外壳移开。
如上所述，焊接设备将保持在原位，直到焊接冷却至预定温度，例如冷却至200℃以下。
图7示出了上述设备的子构件的分解轴测图。图7更清楚地示出了柔性导热条2的上表面，该上表面包含凹形部以接收加热元件15。
图8示出了用于将增强肋3焊接到平坦的层压件结构4上的现场工具的轴测图。在图7的分解图中可见的狭缝隐藏在图8的上部外壳的后方。
狭缝的宽度被选择成尽可能窄，并由能够用于所选材料的机床(锯片)的最小宽度驱动。狭缝越薄，能够适应的表面缺陷或变形的“分辨率”就越高。深度是散热器的柔性和耐用性之间的平衡。狭缝越深则灵活性越高，但是耐用性降低。
另外，导热条也可以通过相同的方式分段。因此，导热条也可以与部件表面紧密匹配。
图9示出了散热器的可替代构造。返回参考图7，散热器包括多个狭缝，这些狭缝从散热器的上表面向下延伸到侧部。由狭缝产生的各个段都联接在一起，如图7中所示。
图9示出了可替代构造，其中，各个段被完全分开，即，在整个散热器上都形成有狭缝。这形成了构成散热器的多个独立段，每一个独立段都能够独立于相邻段移动。
以这种方式划分散热器具有许多优点。
例如，以这种方式划分散热器允许相邻的段相对于彼此更大的移动，并且这允许由焊接工具适应层压表面的表面轮廓的更大的差异。
此外，以这种方式划分多个段防止了由于流过相邻线圈的交流电而在散热器中产生涡电流。这继而防止了涡电流对交流电源产生的电阻。
可以有利地使用电绝缘涂层。这种涂层将有效地防止在完全分开的散热器中产生过量涡电流(因而，可以防止散热器由于加热器中的感应场而被过量加热)。
另一种防止在完全分开的散热器中产生过量涡电流的方式是将散热器之间的接触限制到散热器拐角处。这能够通过将散热器中的小凹部加工到散热器接触表面，同时使拐角与其它散热器接触来实现。由于拐角远离感应线圈，所以拐角中的电接触几乎不会引起由于加热器中的感应场的散热器发热。
图9示出了柔性散热器和导热条2能够适应待焊接的层压件的厚度的较大变化的方式。如图9中所示，层压件结构包括从第一厚度t1倾斜到第二厚度t2的斜面23。散热器5也是可见的，并且能够看到散热器和层压件的连续接触。类似地(但不可见)，柔性导热条2也遵循层压件斜面23的轮廓。
图10是图9中所示的布置的分解图。能够看到散热器5的各个段。类似地，还能够看到线圈的屈曲，其对应于由斜面23引起的层压件的厚度变化。
图11示出了时间与温度关系的导热焊接曲线图，并且示出了焊接过程期间层压件的温度。
具体而言，该曲线图示出了焊接示例材料(诸如UD聚醚酮酮(PEKK))的条件。术语“UD”表示单向，并且是指预浸料层，它仅由一个方向的纤维组成，与织物(机织)预浸料层相反。通常，UD材料的焊接更困难(因为树脂较少)。UD材料主要用于飞机的主要结构，即结构中对飞行至关重要的部件。
用于这种基质系统的材料熔融温度约为330℃，而良好焊接则需要375℃，这与层压件的高压釜固结相似。与加热元件接触的部分的表面温度较高，以获得在堆叠厚度，即形成整个层压件的各个层上的温度梯度。该温度受PEKK系统的降解温度的限制，并保持在490℃以下。不接触加热元件的部分的表面温度应优选地保持固态，因此应<330℃。因此，散热器被构造成确保从焊接区域带走热，以将周围的层压件维持在该温度以下。
已发现感应线圈的频率对于加热效率不是至关重要的，实现最佳焊接所需的精确功率输入取决于线圈的长度和特性。例如，300kHz和30kHz均能够产生高质量的焊接。
也能够采用施加焊接压力的可替代布置，例如能够通过机械臂或弹簧加载布置施加压力。
然而，通过使用软管系统，能够通过检查气动系统中的压力来轻松保证焊接压力。如果使用橡胶块或弹簧，这将更加困难，因为(局部)压力量取决于压缩量和弹簧刚度(可能的校准和老化问题)。此外，如果使用橡胶块，则通过执行焊接过程对橡胶块进行的加热将产生额外的膨胀，进一步使均匀的压力分布复杂化。因而，软管布置提供了许多技术优势。
可选地，散热器和/或柔性导热条可以设置有热电偶，该热电偶允许对施加到线圈上的电流进行实时反馈控制。这允许根据例如图11中所示的期望的焊接条件精确地控制焊缝温度。
本文所述的焊接设备和方法的应用包括(但不限于)：
·蒙皮的加强筋，以产生加强蒙皮；
·加强的机身蒙皮面板的框架；
·扭力箱应用中的蒙皮面板的肋；
·扭力箱应用中的蒙皮面板的梁；
·其它部件的小支架。

Claims (22)

1.一种焊接设备，所述焊接设备用于纤维增强热塑性树脂基材料，所述焊接设备包括：
伸长柔性导热条和伸长散热器，所述伸长散热器绕所述导热条的周边的至少一部分延伸，其中所述伸长散热器被划分成多个段，其中相邻段能够相对于彼此移动，
其中所述伸长散热器包括背衬部和一对侧部，所述一对侧部延伸离开所述背衬部，以限定在所述侧部和所述背衬部之间的空隙，并且
其中借助于狭槽将所述伸长散热器划分成多个段，所述狭槽延伸穿过所述背衬部，并且所述狭槽沿每一个侧部的长度的部分长度延伸。
2.根据权利要求1所述的焊接设备，其中所述伸长柔性导热条呈伸长金属条的形式。
3.根据权利要求2所述的焊接设备，其中所述伸长柔性导热条被划分成多个段。
4.根据权利要求3所述的焊接设备，其中每一个侧部的远侧端限定边缘，所述边缘沿所述伸长散热器的长度延伸，并且所述边缘在使用中被布置成接触纤维增强树脂基材料的表面。
5.根据权利要求4所述的焊接设备，其中被限定在所述侧部的所述远侧端之间的空间限定用于接收所述伸长柔性导热条的空间。
6.根据权利要求5所述的焊接设备，其中在所述伸长柔性导热条与所述伸长散热器的相邻部分之间设置电绝缘体。
7.根据权利要求6所述的焊接设备，其中所述散热器的所述侧部的所述远侧端包括阶梯状轮廓，使得所述伸长柔性导热条的表面与所述阶梯状轮廓的表面匹配，并且所述伸长柔性导热条的垂直边与所述阶梯状轮廓的一边匹配。
8.根据权利要求7所述的焊接设备，其中所述伸长柔性导热条的一部分延伸超过所述散热器的从所述背衬部测量的最远侧极限。
9.根据权利要求8所述的焊接设备，其中所述空隙进一步设有伸长热源，所述伸长热源沿所述设备的长度的至少一部分延伸。
10.根据权利要求9所述的焊接设备，其中所述热源是电感应线圈或电阻加热元件。
11.根据权利要求10所述的焊接设备，进一步包括电导体，其中所述电导体进一步包括：所述导体的第一侧上的第一电绝缘体；以及所述导体的相反的第二侧上的第二电绝缘体。
12.根据权利要求11所述的焊接设备，其中所述电导体的所述第一侧面对所述伸长柔性导热条，并且所述电导体的所述相反侧面对所述散热器内的所述空隙且被布置成被接收在所述空隙内。
13.根据权利要求12所述的焊接设备，进一步包括外壳，所述外壳包括盲凹部，所述盲凹部被布置成接收所述伸长散热器、伸长柔性导热条、电导体和电绝缘体。
14.根据权利要求13所述的焊接设备，其中所述凹部进一步包括可充气软管，所述可充气软管在所述凹部内，并且所述可充气软管在充气时被布置成与所述散热器的所述背衬部之间施加力。
15.根据权利要求14所述的焊接设备，其中在所述可充气软管和所述散热器的所述背衬部之间设置热绝缘体。
16.根据权利要求15所述的焊接设备，其中响应于在使用中被布置成检测焊缝温度的一个或更多个温度传感器而控制加热。
17.一种将第一热塑性构件焊接到第二热塑性构件的方法，焊接设备包括柔性伸长导热条和伸长散热器，所述伸长散热器绕所述柔性伸长导热条的周边的至少一部分延伸，其中所述伸长散热器被划分成多个段，其中相邻段能够相对于彼此移动，所述方法包括使所述焊接设备与所述第一构件形成接触并且施加力的步骤，使得所述伸长散热器和所述柔性伸长导热条变形，使得所述柔性伸长导热条及所述伸长散热器与所述第一构件的表面轮廓匹配，
其中所述伸长散热器包括背衬部和一对侧部，所述一对侧部延伸离开所述背衬部，以限定在所述侧部和所述背衬部之间的空隙，并且
其中借助于狭槽将所述伸长散热器划分成多个段，所述狭槽延伸穿过所述背衬部，并且所述狭槽沿每一个侧部的长度的部分长度延伸。
18.一种用于热塑性基材料的焊接设备，所述焊接设备包括柔性伸长导热条和相关联的散热器，所述散热器从所述柔性伸长导热条的最长边缘侧向延伸，其中所述散热器能够沿所述柔性伸长导热条的长度变形，以便在使用中与待焊接的所述热塑性基材料中的变形匹配，
其中所述散热器包括背衬部和一对侧部，所述一对侧部延伸离开所述背衬部，以限定在所述侧部和所述背衬部之间的空隙，并且
其中借助于狭槽将所述散热器划分成多个段，所述狭槽延伸穿过所述背衬部，并且所述狭槽沿每一个侧部的长度的部分长度延伸。
19.一种用于热塑性基材料的焊接设备，所述焊接设备包括：
柔性伸长导热条和相关联的热源，所述热源被布置成在第一方向上将热引导至待焊接的层压件表面；和
散热器，所述散热器从所述柔性伸长导热条的最长边缘侧向延伸，并被布置成从所述层压件表面收集热并将热在第二相反方向上传递，
其中所述散热器能够沿所述柔性伸长导热条的长度变形，以便在使用中与待焊接的热塑性基材料中的变形匹配，
其中所述散热器包括背衬部和一对侧部，所述一对侧部延伸离开所述背衬部，以限定在所述侧部和所述背衬部之间的空隙，并且
其中借助于狭槽将所述散热器划分成多个段，所述狭槽延伸穿过所述背衬部，并且所述狭槽沿每一个侧部的长度的部分长度延伸。
20.一种计算机控制机器人臂，包括根据权利要求1至16中的任一项所述的焊接设备。
21.一种计算机系统，包括根据权利要求1至16中的任一项所述的焊接设备。
22.一种操作计算机控制机器人臂的方法，包括根据权利要求17所述的方法。
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