CN112622281A - 用于聚合物和聚合物复合材料的超声焊接的设备 - Google Patents

用于聚合物和聚合物复合材料的超声焊接的设备 Download PDF

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CN112622281A
CN112622281A CN202011008030.9A CN202011008030A CN112622281A CN 112622281 A CN112622281 A CN 112622281A CN 202011008030 A CN202011008030 A CN 202011008030A CN 112622281 A CN112622281 A CN 112622281A
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tip
horn
radius
knurl
shank
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CN112622281B (zh
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P.王
T.H.李
B.J.布拉斯基
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GM Global Technology Operations LLC
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
    • B23K20/106—Features related to sonotrodes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • 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
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
    • 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
    • B29C66/40—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
    • 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
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    • 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
    • B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • 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
    • B29C66/8141—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 surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81411—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 surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat
    • B29C66/81421—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 surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave
    • B29C66/81422—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 surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave being convex
    • 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
    • B29C66/8141—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 surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81433—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 surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined being toothed, i.e. comprising several teeth or pins, or being patterned
    • 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
    • B29C66/83—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
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/95—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94
    • B29C66/959—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 characterised by specific values or ranges of said specific variables
    • B29C66/9592—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 characterised by specific values or ranges of said specific variables in explicit relation to another variable, e.g. X-Y diagrams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/36—Electric or electronic devices
    • 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
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    • B29C66/92—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/929—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges
    • B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract

提供一种用于一个或多个部件的工件的超声焊接的设备。该设备包括焊头，该焊头配置成接触工件并将能量传递到工件。焊头包括柄和设置在柄的面对工件的端部处的尖端。尖端具有一面，该面具有在该面处形成弯曲表面的尖端半径。在穿过弯曲表面的面上形成滚花。

Description

用于聚合物和聚合物复合材料的超声焊接的设备
技术领域
本公开总体上涉及焊接，并且更具体地涉及使用一设备的聚合物和聚合物复合材料的超声焊接，所述设备具有带有优化的滚花(knurl)和优化的焊头(horn)尖端表面半径的焊头。
背景技术
焊接是接合部件的最常见形式之一。超声波焊接通常用于接合聚合物部件，尤其是那些由热塑性材料制成的部件，也可以用于接合金属部件。在超声波焊接中，塑料或金属部件被夹在焊接焊头和砧座之间。为了利用超声波能量进行焊接，将高频振动施加到要通过焊头的高频振动接合的部件上。焊头也可以称为超声波焊极，它是产生超声波振动的工具的广义术语，该超声波振动施加到工件或材料上，例如用于焊接、机械加工或混合。在焊接的情况下，由于施加的机械力和由机械振动在部件之间的界面处生成的热量而导致发生部件接合。
使用超声波焊接来提供一致的焊接质量需要克服多个挑战。必须精确设定包括夹紧载荷、振动幅度和焊接时间在内的过程变量，并且必须考虑堆叠高度和材料的变化。在进行塑料焊接时，夹紧力必须保持足够低，以免部件变形，而较硬的材料则需要更高的夹紧载荷。如果夹紧力太低或发生不对准，可能会导致焊缝(weld)形成不足。
因此，期望提供一种用于超声波焊接的设备，该设备被设计为有效率地且有效地克服相关的挑战。此外，结合附图以及前述技术领域和背景技术，根据随后的详细描述和所附权利要求，本发明的其他期望特征和特性将变得显而易见。
发明内容
提供用于工件的超声波焊接的设备，其可以包括多个部件。在各个实施例中，设备包括焊头，该焊头配置成接触工件并将能量传输到工件。焊头包括柄(shank)和设置在柄的面对工件的端部处的尖端。该尖端具有一面，该面的尖端半径在该面处形成弯曲表面。在穿过弯曲表面的面上形成滚花。
在另外的实施例中，滚花由滚花角度和滚花节距(pitch)限定。
在另外的实施例中，柄是圆柱形形状的，并且尖端被成形为截头球形的扇区(sector)。
在另外的实施例中，尖端半径将尖端限定为从柄延伸的凸形几何结构。
在另外的实施例中，焊头具有沿着柄的焊头半径。滚花具有与尖端半径和焊头半径成比例的几何结构。
在另外的实施例中，焊头具有沿着柄的焊头半径。尖端半径与焊头半径的比率在大约4到大约5的范围内。
在另外的实施例中，滚花包括以滚花节距布置的多个齿。滚花节距与焊头半径的比率在约0.09至约0.13的范围内。
在另外的实施例中，滚花包括多个齿。每个齿具有在大约40度到大约60度的范围内的滚花角。
在另外的实施例中，滚花角是从齿的一侧到穿过垂直于焊头的中心线的面延伸的平面测量的。
在另外的实施例中，工件包括聚合物复合材料和聚合物材料中的至少一种。
在各种其他实施例中，一种用于工件的超声波焊接的设备，包括一个或多个部件，该设备包括焊头，该焊头配置成接触工件并将振动能量传递到工件。焊头包括具有横向尺寸的柄。尖端设置在柄的面向工件的端部处，并且具有带有尖端半径的面。尖端半径将尖端限定为从柄延伸的凸形几何结构。滚花形成在该面上。
在另外的实施例中，柄是圆柱形形状的。横向尺寸为焊头半径，尖端被成形为截头球形的扇区。
在另外的实施例中，焊头具有沿着柄的焊头半径。凸形几何结构被限定为与尖端半径和焊头半径成比例。
在另外的实施例中，横向尺寸是沿着柄的焊头半径。尖端半径与焊头半径的比率在大约4到大约5的范围内。
在另外的实施例中，滚花包括以滚花节距布置的多个齿。滚花节距与焊头半径的比率在约0.09至约0.13的范围内。
在另外的实施例中，滚花包括多个齿。每个齿具有在大约40度到大约60度的范围内的滚花角。
在另外的实施例中，滚花角是从齿的一侧到穿过垂直于焊头的中心线的面延伸的平面测量的。
在另外的实施例中，柄具有焊头半径(R)，面具有尖端半径(r)，滚花具有滚花节距(d)，焊头由r/R＝4-5和d/R＝0.09-0.13限定，并且滚花具有40-60度的滚花角。
在另外的实施例中，横向尺寸是沿着柄的焊头半径。尖端半径与焊头半径的比率在大约4到大约5的范围内。滚花包括以滚花节距布置的多个齿。滚花节距与焊头半径的比率在约0.09至约0.13的范围内。每个齿具有约40度至约60度的滚花角。
在各种其他实施例中，用于一个或多个部件的工件的超声波焊接的设备包括焊头，该焊头配置成接触工件并将能量传递到工件。焊头包括具有尖端的柄，该尖端设置在柄的面向工件的端部处。尖端具有带有滚花的面。柄具有焊头半径(R)，所述面具有尖端半径(r)，滚花具有滚花节距(d)，焊头由r/R＝4-5和d/R＝0.09-0.13限定，并且滚花具有40-60度的滚花角。
附图说明
在下文中，将结合以下附图描述示例性实施例，其中，相同的附图标记表示相同的元件，并且在附图中：
图1是根据各个实施例的超声焊接设备的示意图；
图2是根据各个实施例的图1的设备的焊接焊头的示意图；
图3是根据各个实施例的图2的焊接焊头的面的端视图；
图4是根据各个实施例的、大体上通过图3的线4-4截取的局部截面图；
图5是根据各个实施例的图3的焊接面的滚花的示意图；
图6是竖直轴上的焊接区域相对于水平轴上的各种尖端半径选项的图形表示；
图7是竖直轴上的焊接区域相对于水平轴上的各种滚花角选项的图形表示；和
图8是竖直轴上的焊接区域与水平轴上的各种滚花节距选项的图形表示。
具体实施方式
以下详细描述本质上仅是示例性的，并不旨在限制本申请和使用。此外，无意受到在先前技术领域、背景技术、发明内容或以下详细描述中提出的任何明示或暗示的理论的约束。
如本文所公开的，超声波焊接是通过最佳设计的焊接焊头完成的。已经发现，用于结构应用(例如某些聚合物和包括碳纤维增强的聚酰胺6等的聚合物复合材料)的相对硬塑料的超声焊接代表了独特的挑战。如本公开中所述的，对焊接焊头的设计进行了优化，以避免诸如打滑之类的结果，并始终如一地产生良好的焊缝尺寸和强度。在本文所述的多个实施例中，焊接焊头可包括滚花尖端，其中各个滚花元件具有最佳的节距高度和角度以产生期望的焊接效果。另外，与常规的平尖端的焊头不同，本文公开的焊接焊头可以具有针对期望的焊缝形成而优化的尖端曲率。
参考图1和2，示出了超声波类型的焊接设备20。设备20包括焊头22和砧座24，在焊头22和砧座24之间夹持包括一个或多个部件的工件26。在该示例中，工件26包括将被焊接在一起的两个部件28、30。在其他实施例中，可以包括更少或更多的工件。砧座由固定装置32支撑以防止移动。设备20包括超声堆34，超声堆34包括焊头22以及转换器/升压器(booster)36。转换器/升压器36将电信号转换成机械振动38并产生振动38的幅度。焊头22施加振动38到部件28、30。振动频率通常在20-40千赫兹的范围内。焊头面40处的振动38的运动传递到两个部件28、30。振动38移动穿过部件28，并在部件28、30之间的界面43处产生摩擦和粘弹性变形。结果，在界面43处产生热量，其使材料熔化，该材料在冷却时形成将部件28、30融合在一起的焊缝。
通常，焊头22具有柄23和在柄23的面向工件26的端部27处的尖端25。在当前实施例中，焊头22具有在尖端呈圆形的面40，形成凸的几何结构，这导致夹紧力和振动38在比平焊头尖端小的区域上施加到部件28、30上。已经发现所产生的较高的力与面积之比对焊接较硬的材料是有益的。面40具有尖端半径(r)42，并且通常成形为球形的截头扇区。尖端半径42产生曲率，使得面40本质上是凸形的，并且在其焊头中心线46处比其外边缘更厚，面40包括弯曲表面41。尖端半径42可以容纳不对准，例如与焊头22和部件28之间的垂直线略有偏离。焊头22的主体44在其柄23处通常为圆柱形的，并围绕中心线46形成，焊头半径(R)48为在焊头22的柄23处的横向尺寸。半径48至少在邻近尖端25的区段处沿着柄23是连续的，并且将柄23限定为以中心线46为中心的实心圆柱体。焊头22的半径48确定面40的总体外周尺寸，并且尖端半径42可以变化，如下文进一步描述的。
焊头22的面40的细节在图3和4中示出。面40包括由多个滚花元件形成的滚花50，作为均匀分布的单个齿52。在当前实施例中，滚花50为在面40上以菱形图案形成由坡口(groove)隔开的成行和成列的齿52。在其他实施例中，滚花50可以形成为对角线、笔直、环形、其组合或另一图案的图案。齿52各自从面40向外突出并且各自形成为棱锥形状，并且具体地在该示例中为四棱锥。在其他实施例中，齿52可以形成为其他形状，例如三边形、圆锥形或另一种形状。
图5中示意性地示出了多个齿52。齿52在沿着一行或列的滚花50的每个方向上通过均匀的滚花节距(d)54彼此分开。滚花节距54是从一个齿52的中心56到相邻的齿52的中心58的距离。每个齿52还具有滚花角(θ)65。滚花角65是齿52的每侧62与延伸穿过垂直于焊头22的中心线46的面40延伸的平面64之间的角度。滚花节距54和滚花角65确定齿52的尺寸，包括高度(h)66。
已经发现，包括滚花50的几何形状和尖端半径42的焊头22的设计变量影响焊接性能。已经发现，以某些优化的焊头几何形状减少焊头打滑可导致改善的焊缝质量。已经进行了实验分析，包括研究在两个工件堆叠的情况下焊头22的三种几何选项在聚合物复合材料的超声焊接中的焊接性能，每个工件的厚度为3毫米。表1示出了三个几何选项A，B和C的规格。
选项 尖端半径42(毫米) 滚花角65(度) 滚花节距54(毫米)
A 32.74 30 0.75
B 36.69 45 1.00
C 40.64 60 1.25
表1
在250牛顿的触发力、0.25毫米/秒的焊头速度和100微米(±50μm)的幅度范围内，根据选项A，B和C的由焊头22形成的焊缝的实验分析结果示出在图6-8中。具体地，根据选项A，B和C，示出了在特定焊接时间形成的焊接区域的尺寸，其尖端半径42、滚花角65和滚花节距54有所变化。图6-8示出在0.6秒的焊接时间下竖直轴70、72、74上的焊接面积(以平方毫米为单位)与针对图6中的每个尖端半径42、图7中的滚花角65和图8中的滚花节距54的水平轴80、82、84上的选项A，B和C的规格相比。
关于焊头22的尖端半径42，如图6所示，选项A导致大约55平方毫米的焊接面积，选项B导致大约28平方毫米的焊接面积，而选项C导致大约37平方毫米的焊接面积。这些结果表明，对于焊接时间为0.6秒下的尖端半径42，选项A导致了优选的最大焊接面积。图7示出，对于焊头22的滚花角65，选项A导致大约24平方毫米的焊接面积，选项B导致大约48平方毫米的焊接面积，以及选项C导致大约47平方毫米的焊接面积。这些结果表明，对于焊接时间为0.6秒下的滚花角65，选项B导致了优选的最大焊接面积。图8示出，对于焊头22的滚花节距54，选项A导致大约48平方毫米的焊接面积，选项B导致大约38平方毫米的焊接面积，以及选项C导致大约34平方毫米的焊接面积。这些结果表明，对于焊接时间为0.6秒下的滚花节距54，选项A导致了优选的最大焊接面积。
已经在各种焊接时间(包括0.7秒、0.8秒和0.9秒)下进行了附加实验。在每种情况下，已确定尖端半径42的选项A产生了最大的焊接面积，滚花角65的选项B产生了最大的焊接面积，滚花节距54的选项A产生了最大的焊接面积。换句话说，最小的评估尖端半径42、中等尺寸的评估滚花角65和最小评估的滚花节距54产生了最佳结果。因此，优化的焊头22具有大约32.74毫米的尖端半径42，具有大约45度的优化的滚花角65和具有大约0.75毫米的优化的滚花节距54。还表明了较大的尖端半径42产生的焊接面积明显较小，60度的滚花角65产生的结果与45度的滚花角大致一样好，而较大的滚花节距54的距离产生的焊接面积则明显较小，与选项A的滚花节距54相比。
还已经发现，焊头22的尺寸影响尖端半径42和滚花节距54的最佳值。因此，最佳尖端半径42和最佳滚花节距54可能与焊头22的尺寸有关，特别是与焊头半径48有关。可以推断出实验结果，以角度和比例来限定焊头22。如上所示，最佳焊头22的滚花角约为40-60度。另外，使用7毫米的焊头半径48、尖端半径42与焊头半径48的比率(r/R)可以由4.0至5.0的最佳范围以及由4.66的优选比率来限定。同样，滚花节距54与焊头半径48的比率(d/R)可以由0.09至0.13的最佳范围和由0.11的优选比率来限定。因此，已经发现优化的焊头22具有40-60度的滚花角65、4.0-5.0的尖端半径42与焊头半径48的比率以及0.09-0.13的滚花节距54与焊头半径48的比率。滚花节距54与焊头半径48(d/R)的比率，以及尖端半径42决定了面40上的滚花齿52的数量。已经发现，优化的焊头22产生较大的焊接面积，部分地是由于减少了打滑和向工件界面43的最佳能量传递。
因此，用于超声焊接的设备包括优化的几何形状以产生期望的焊缝特性。尽管在前面的详细描述中已经提出了至少一个示例性实施例，但是应当理解，存在大量的变型。还应当理解，一个或多个示例性实施例仅是示例，并且无意以任何方式限制本公开的范围、适用性或配置。相反，前述详细描述将为本领域技术人员提供用于实施一个或多个示例性实施例的便利路线图。应该理解的是，在不脱离所附权利要求及其合法等同物所阐述的本公开的范围的情况下，可以对元件的功能和布置进行各种改变。

Claims (10)

1.一种用于一个或多个部件的工件的超声焊接的设备，该设备包括：
焊头，配置成接触所述工件并将能量传递到所述工件，所述焊头包括：
柄；
尖端，设置在柄的面向工件的端部处，该尖端具有具有尖端半径的面，使得尖端在该面处具有弯曲表面；和
在穿过弯曲表面的面上的滚花。
2.根据权利要求1所述的设备，其中，所述滚花由滚花角和滚花节距限定。
3.根据权利要求1所述的设备，其中，所述柄是圆柱形形状的，并且所述尖端成形为截头球形的扇区。
4.根据权利要求1所述的设备，其中，所述尖端半径将所述尖端限定为从所述柄延伸的凸形几何结构。
5.根据权利要求1所述的设备，其中：
焊头具有沿着所述柄的焊头半径，和
其中，滚花具有与尖端半径和焊头半径成比例的几何结构。
6.根据权利要求1所述的设备，其中，所述焊头具有沿着所述柄的焊头半径，其中，所述尖端半径与所述焊头半径的比率在大约4至大约5的范围内。
7.根据权利要求1所述的设备，其中，所述滚花包括以滚花节距布置的多个齿，其中，所述滚花节距与所述焊头半径的比率在大约0.09至大约0.13的范围内。
8.根据权利要求1所述的设备，其中：
滚花包括多个齿；和
每个齿具有在大约40度到大约60度的范围内的滚花角。
9.根据权利要求8所述的设备，其中，所述滚花角是从齿的一侧到穿过垂直于所述焊头的中心线的面延伸的平面测量的。
10.根据权利要求1所述的设备，其中：
所述柄具有焊头半径(R)；
所述面具有尖端半径(r)；
所述滚花具有滚花节距(d)；
所述焊头由r/R＝4-5和d/R＝0.09-0.13限定；和
所述滚花具有40-60度的滚花角。
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