CN115674690A - 用于将热塑性部件彼此焊接的焊接设备和方法 - Google Patents

用于将热塑性部件彼此焊接的焊接设备和方法 Download PDF

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Publication number
CN115674690A
CN115674690A CN202210831905.8A CN202210831905A CN115674690A CN 115674690 A CN115674690 A CN 115674690A CN 202210831905 A CN202210831905 A CN 202210831905A CN 115674690 A CN115674690 A CN 115674690A
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China
Prior art keywords
thermoplastic
welding
component
mould
extension
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CN202210831905.8A
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English (en)
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约尔格·施维克特
菲利普·克勒
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Airbus Operations GmbH
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Airbus Operations GmbH
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    • 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
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
    • B29C66/474—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially non-flat
    • 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
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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
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B29C66/8181—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 cooling constructional aspects
    • B29C66/81811—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 cooling 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
    • B29C66/82—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps
    • B29C66/824—Actuating mechanisms
    • B29C66/8242—Pneumatic or hydraulic drives
    • 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
    • B29C66/84—Specific machine types or machines suitable for specific applications
    • B29C66/863—Robotised, e.g. mounted on a robot arm

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

本申请涉及用于将热塑性部件彼此焊接的焊接设备和方法。在一个方面中，描述了一种用于将热塑性部件彼此焊接的焊接设备(100)。所述设备(100)包括焊接装置(105)和模具(120)，所述焊接装置被配置为熔化所述热塑性部件中的第一热塑性部件(10)与所述热塑性部件中的第二热塑性部件(20)之间的界面，所述模具被配置为将所述第一热塑性部件(10)的边缘区域按压到所述第二热塑性部件(20)上。特别地，所述模具(120)具有延伸部(125)，所述延伸部在所述边缘区域处覆盖所述第一热塑性部件(10)的侧面(12)、并且接触所述第二热塑性部件(20)。

Description

用于将热塑性部件彼此焊接的焊接设备和方法
技术领域
本发明涉及一种将热塑性部件彼此焊接的焊接设备和方法。特别地，本发明涉及一种焊接设备和焊接方法，该焊接设备和焊接方法采用了覆盖一个热塑性部件的侧面并接触另一个热塑性部件的模具。
背景技术
热塑性部件、特别是热塑性复合材料部件的焊接通常是通过加热部件、施加静压力以及使两个待焊接部件固结来完成的。需要压力以将两个部件轻微移动到一起，以便两个部件的热塑性材料一旦因受热而熔化就会彼此融合和混合。
然而，已经发现，至少由于施加压力，一小部分热塑性材料(也称为“聚合物”)在两个待焊接部件的界面端部处被挤出。因此，可能在焊接的部件中形成空隙。由于固结力(压力)也因挤出的聚合物而局部降低，两个部件可能发生局部固结。
另外，在纤维增强热塑性复合材料的情况下，取决于熔融聚合物层的厚度，一些纤维也可能在两个待焊接部件的界面端部处被挤出。这可能导致纤维变形和部件的机械性能降低，因为纤维不再处于所需方向和/或未正确嵌入热塑性材料中。
因此，本发明的目的是克服所发现的和上面提到的缺点、并且提供一种增强热塑性部件彼此焊接的焊接设备和方法。
发明内容
此目的通过具有如下文所述的特征的用于将热塑性部件彼此焊接的焊接设备以及具有如下文所述的特征的将热塑性部件彼此焊接方法来实现。
此外，还限定有优选实施例。
根据为了更好地理解本披露内容的第一示例性方面，一种用于将热塑性部件彼此焊接的焊接设备包括焊接装置和模具，该焊接装置被配置为至少熔化这些热塑性部件中的第一热塑性部件与这些热塑性部件中的第二热塑性部件之间的界面，该模具被配置为将第一热塑性部件的边缘区域按压到第二热塑性部件上。
另外，模具可以具有延伸部，该延伸部在边缘区域处覆盖第一热塑性部件的侧面，并且该延伸部接触第二热塑性部件。第一热塑性部件的边缘区域是第一热塑性部件的在其边界区域中的一部分，即沿着第一热塑性部件终止处的边缘。这可以在第一热塑性部件的一侧以及在第一热塑性部件的两侧的拐角处。
应当注意，第一热塑性部件至少在其焊接到第二热塑性部件的区域中、即在由第一热塑性部件与第二热塑性部件之间的界面形成的区域中可以比在垂直于界面的方向(也称为第一热塑性部件的厚度方向)上更大。因此，第一热塑性部件的侧面是第一热塑性部件的在厚度方向上并且沿着第一热塑性部件的边缘(边界)延伸的表面，其中，该边缘界定了侧面。与第二热塑性部件的界面由第一热塑性部件的也界定侧面的另一边缘(边界)界定。
由于模具的延伸部覆盖第一热塑性部件的侧面并且接触第二热塑性部件，第一热塑性部件与第二热塑性部件之间的界面的端部被延伸部封闭。因此，避免或至少减少了熔融热塑性材料的挤出。如果在界面处挤出少量的熔融热塑性材料，则延伸部可以密封焊接线(的开放端部)。例如，挤出的熔融热塑性材料通过延伸部展开在焊接线上，即展开在沿第一热塑性部件的侧面的界面的端部上。这提供了保护，免受例如由于水和/或化学物质的侵入而造成的环境影响。
此外，第一热塑性部件和/或第二热塑性部件的任何纤维都通过延伸部来稳定，使得这些纤维不能在第一热塑性部件和第二热塑性部件的界面区域中被挤出。即使熔融热塑性材料中的纤维在焊接过程中移动，挤出的熔融热塑性材料也会通过延伸部展开在这些纤维上。这允许实现以改进焊缝焊接的热塑性部件的高品质结构，并且产生更均匀的焊接品质。
在实施方式变体中，延伸部的至少一部分可以被配置为固化熔融热塑性材料，特别是任何挤出的材料。例如，延伸部的表面可能足够冷，以固化熔融聚合物。当然，至少延伸部的与熔融热塑性材料接触的部分可以被主动冷却，即例如通过温度控制装置进行温度控制。这种温度控制装置可以用冷却流体和/或电冷却元件来操作。
在另一实施方式变体中，延伸部的至少一部分可以由金属或陶瓷材料制成。这些材料是导热的，这有助于其主动冷却，并且可以具有实现平滑密封焊缝的光滑表面。
在又一实施方式变体中，可以例如通过温度控制装置主动加热延伸部的至少一部分，以便在待焊接的区域中实现第一热塑性部件和第二热塑性部件的均匀温度。这改善了聚合物分子在焊缝处的扩散。这种温度控制装置可以用加热流体和/或电加热元件来操作。
在另外的实施方式变体中，焊接设备可以进一步包括柔性按压装置，该柔性按压装置被配置为将模具按压到第一热塑性部件和/或第二热塑性部件上。例如，按压装置作用在模具的端部上，该端部与模具的接触第一热塑性部件和/或第二热塑性部件的表面相反。因此，第一热塑性部件可以机械地固定到第二热塑性部件，使得它们在焊接之前和在焊接时不会相对于彼此移动。
另外，按压装置可以被配置为调节施加到第一热塑性部件上的力，使得在第一热塑性部件和第二热塑性部件的界面处施加固结压力，这允许实现聚合物在第一热塑性部件和第二热塑性部件的熔融表面处的流动最小。
此外，按压装置可以被配置为具有一定的柔性。特别地，按压装置可以在平行于由按压装置施加到第一热塑性部件和/或第二热塑性部件上的力的方向上是柔性的。这允许在第一热塑性部件和第二热塑性部件上沿着第一热塑性部件和/或第二热塑性部件的表面(即，基本上垂直于由按压装置施加的力的方向)移动按压装置(例如与焊接设备一起)，并且进一步允许适应第一热塑性部件和/或第二热塑性部件的不同厚度。
例如，按压装置可以包括囊袋或活塞，其允许按压装置沿着或平行于所施加的力的方向移动。因此，模具或其至少一部分可以容忍第一热塑性部件和/或第二热塑性部件上的任何不平坦部分，同时保持所需的固结压力。
在又一另外的实施方式变体中，模具可以被分成多个模具部分，每个模具部分被配置为在平行于由模具施加到第一热塑性部件和第二热塑性部件上的压力的方向上相对于其他模具部分移动。这种模具可以更好地适配第一热塑性部件和/或第二热塑性部件的表面，特别是可以更好地适配第一热塑性部件和/或第二热塑性部件的相邻部分的不同厚度。因此，每个模具部分可以根据第一热塑性部件和/或第二热塑性部件的厚度和/或表面特性上下移动。
在特定的实施方式变体中，模具的延伸部可以被分成该多个模具部分。换言之，仅模具的延伸部被分成多个部分。当然，模具的除延伸部之外的任何其他部分都可以被分成该多个模具部分。同样，整个模具可以被分成该多个模具部分。
在实施方式变体中，焊接装置可以是超声焊接工具头(sonotrode)。这允许将超声(高频)振动引入到第一热塑性部件和/或第二热塑性部件中。这种振动在第一热塑性部件和第二热塑性部件的界面处的表面处引起边界摩擦，从而使表面加热和熔化。由模具引起的所施加压力实现了聚合物分子在焊缝处的均匀扩散。超声焊接进一步允许更快的焊接时间，因为将要被熔化并因此之后必须进行冷却的热塑性材料只是一小部分。
替代性地或附加地，焊接装置可以包括热源，该热源被配置为将热辐射或传导到第一热塑性部件和/或第二热塑性部件中。这种热源允许在第一热塑性部件和第二热塑性部件中实现均匀的温度分布。
此外，热源可被配置为不熔化热塑性材料，而仅使第一热塑性部件和/或第二热塑性部件升温，而焊接并因此熔化是通过比如超声工具头等另一焊接装置来实现的。
在另一个实施方式变体中，焊接设备可以进一步包括移动装置，该移动装置被配置为使焊接设备相对于第一热塑性部件和第二热塑性部件移动。这种移动装置允许实现沿着特定路径的纵向焊缝。例如，焊缝可以沿着直线形成，或者可以是弯曲的，或者可以由彼此相邻的多条直线组成、形成焊接区域。
在另外的实施方式变体中，模具的延伸部可以在拐角处具有凹处(cavity)，该凹处被配置为布置在第一热塑性部件的侧面与第二热塑性部件之间的区域中。换言之，第一热塑性部件的侧面与第二热塑性部件之间的拐角在它们的界面处由于凹处而不与模具的延伸部接触。例如，延伸部可以在延伸部的与第一热塑性部件的侧面和第二热塑性部件的表面分别接触的两侧的拐角处被倒角。这种凹处允许任何熔融热塑性材料、例如在焊接期间挤出的熔融热塑性材料填充第一热塑性部件的侧面与第二热塑性部件之间的拐角。因此，在界面的端部处，焊缝可以用圆角密封。
在又一实施方式变体中，焊接装置和模具的第一部分可以组合在集成装置中。因此，可以构建紧凑的焊接设备，其中焊接装置甚至可以使用在边缘区域中，即靠近第一热塑性部件的边界或直接在第一热塑性部件的边界上。
可选地，模具的第二部分可以形成或包括延伸部。第二部分可以固定到模具的第一部分或者可以相对于第一部分是可移动的，从而第一热塑性部件和第二热塑性部件的厚度方向上的任何差异可以被调平或补偿。
根据为了更好地理解本披露内容的第二示例性方面，一种将热塑性部件彼此焊接的方法包括将模具朝向这些热塑性部件中的第二热塑性部件按压到这些热塑性部件中的第一热塑性部件的边缘区域上、以及至少将第一热塑性部件与第二热塑性部件之间的界面加热到第一热塑性部件和第二热塑性部件的相应材料的熔化温度。该方法进一步包括将模具的延伸部放置成在边缘区域处靠近第一热塑性部件的侧面并且放置到第二热塑性部件上。将延伸部放置成靠近第一热塑性部件的侧面减少了熔融热塑性材料的挤出，稳定了第一热塑性部件和/或第二热塑性部件中的任何纤维，和/或特别是在第一热塑性部件和第二热塑性部件的界面的端部处密封了焊缝。
在实施方式变体中，加热可以包括通过将来自超声焊接工具头的超声波至少施加到第一热塑性部件中来加热第一热塑性部件和第二热塑性部件。可以以如下方式调整超声波的施加，即，使得第一热塑性部件和第二热塑性部件的表面由于超声振动而相互摩擦。干摩擦产生热量，直到表面熔化，从而可以通过将模具按压到至少第一热塑性部件上而将这些表面焊接在一起。
替代性地或附加地，可以使用另一个热源来加热第一热塑性部件和第二热塑性部件的材料。这有助于热塑性材料的熔化。
在另一个实施方式变体中，该方法可以进一步包括在第一热塑性部件与第二热塑性部件之间的界面处设置能量引导器。能量引导器可以由与焊接伙伴(即第一热塑性部件和第二热塑性部件)相同的材料/聚合物组成。能量引导器可以被配置为在第一热塑性部件和/或第二热塑性部件的表面之前熔化，从而在焊接过程开始时在第一热塑性部件和第二热塑性部件的界面处提供熔融材料。这有助于热量分布和热量进入第一热塑性部件和/或第二热塑性部件的表面。
例如，能量引导器可以是置于第一热塑性部件与第二热塑性部件之间的薄的热塑性材料片材。替代性地，能量引导器可以形成在第一热塑性部件和/或第二热塑性部件的表面上。
替代性地或附加地，能量引导器可以包括或者是(点状、纵向、弯曲的等)突出部，这些突出部形成在片材的表面上或形成在第一热塑性部件和/或第二热塑性部件的表面上。由于模具施加的力作用在这些突出部上，突出部将首先熔化并开始焊接。
在又一实施方式变体中，该方法可以进一步包括至少使模具沿着第一热塑性部件的边缘区域移动，其中，模具的延伸部的放置包括使模具的延伸部沿着第一热塑性部件的侧面和沿着第二热塑性部件滑动。因此，可以实现例如沿着第一热塑性部件的边缘(边界)的纵向或弯曲的焊缝。取决于焊接装置，如果焊接装置在第一热塑性部件和第二热塑性部件中实现更大面积的熔融热塑性材料，则仅模具可以移动。然后，移动的模具仅施加必要的焊接压力，包括熔融聚合物的分布和扩散，以及通过延伸部密封第一热塑性部件与第二热塑性部件之间的界面端部。
当然，在实施方式变体中，模具和焊接装置可以一起移动。因此，相关联的焊接设备可以在运动方向上保持较小。焊接设备实际上可以构建为进行点焊，而移动模具和焊接装置来实现长形焊缝。
本披露内容不受限于以所描述的形式和顺序的方面和变体。具体地，各方面和变体的描述不应被理解为特征的特定限制分组。应当理解的是，本披露内容还涵盖未明确描述的各方面和变体的组合。因此，每个变体或可选特征可以与任何其他方面、变体、可选特征或甚至其组合进行组合。
附图说明
现在参照附图更详细地解释本发明的优选实施例，在附图中：
图1示意性地展示了示例性焊接设备和待焊接部件的截面；
图2示意性地展示了另一示例性焊接设备和待焊接部件的截面；
图3示意性地展示了示例性焊接设备和待焊接部件的沿移动方向的截面；以及
图4展示了焊接热塑性部件的方法的示例性流程图。
具体实施方式
图1示意性地展示了示例性焊接设备100的截面。焊接设备100用于将第一热塑性部件10焊接到第二热塑性部件20。例如，第一部件10和第二部件20可以是具有或不具有纤维增强的热塑性部件。部件10、20可以通过至少在第一部件10和第二部件20的彼此接触并要焊接到彼此的表面处加热和熔化热塑性材料(聚合物)来彼此焊接。通过熔化热塑性材料，第一部件10和第二部件20的聚合物分子将彼此融合和互锁，从而对两个部件10、20进行焊接。
焊接设备100可以包括焊接装置105，该焊接装置被配置为至少熔化第一热塑性部件10与第二热塑性部件20之间的界面。焊接装置105可以是将热量辐射和/或传导到部件10、20之一的热源。在此，上部件是第一部件10，从而加热焊接装置105在厚度方向(Z轴)上完全加热第一部件10的热塑性材料、并且加热第二部件20的至少一部分。例如，在第一部件10与第二部件20之间的界面处，第二部件20的表面可以被加热和熔化以在第一部件10和第二部件20的界面处实现两个表面的焊接。
替代性地或附加地，焊接装置105可以包括超声焊接装置105，例如工具头。这种工具头将高频超声波发射到第一部件10和第二部件20中。由于第一部件10和第二部件20的彼此接触的表面处的干摩擦，这些表面(在界面区域中)升温并且熔化，从而它们可以焊接。
应当理解，焊接设备100不受限于这些类型的焊接装置105，而是还涵盖在第一部件10和第二部件20的界面区域中实现两个部件10、20的至少部分熔化的任何焊接装置105。
为了有助于焊接，可以使用能量引导器30。例如，能量引导器30可以包括热塑性材料或由热塑性材料制成，该热塑性材料优选地与第一部件10和/或第二部件20的相同。能量引导器可以具有放置在第一部件10与第二部件20之间的界面区域中的片材的形式。可选地，能量引导器30可以包括突出元件(未示出)或仅由突出元件制成，这些突出元件在厚度方向(Z轴)上突出并且布置在其他方向(X轴和Y轴)的区域中。特别是在使用超声工具头时，这样的突出元件将受到第一部件10与第二部件20之间的摩擦，从而这些突出元件将首先熔化并且实现热量进入到第一部件10和第二部件20的相应表面中。
焊接设备100进一步包括模具120，该模具被配置为至少将第一热塑性部件10的边缘区域按压到第二热塑性部件20上。可以优化由模具120施加的压力，以用于第一部件10和第二部件20的焊接。例如，可以根据热塑性材料的类型来控制所施加的压力并将其设定为最佳焊接压力。由于压力，第一部件10和第二部件20的熔融表面移动，这导致热塑性聚合物分子的融合和互锁。
模具120可以包括延伸部125或仅由延伸部组成，该延伸部在边缘区域处覆盖第一热塑性部件10的侧面12并且进一步接触第二热塑性部件20。优选地，如果第二部件20沿X轴或Y轴方向在第一部件10的侧面12上延伸，则延伸部125接触第二热塑性部件20的上表面。替代性地，如果第一部件10和第二部件20具有连续(齐平)的侧面(即，第二部件20将在图1的左侧以第一部件10的侧面12结束，而不是所展示的延伸出的第二部件20)，延伸部125可以在第二部件20的这种侧面处接触第二热塑性部件20。
在任何情况下，延伸部125布置在第一部件10与第二部件20之间的界面的端部处、并且封闭界面的这个开放端部。因此，当第一部件10和第二部件20彼此焊接时，界面的开放端部被延伸部125覆盖，并且任何熔融热塑性材料均被延伸部125阻止流出。这有助于封闭焊缝，尤其是在界面的开放端部。
如图1所展示的模具120包括(被分成)至少两个部分，即部分122和延伸部125。这两个部分可以布置成使得它们各自的下端(Z轴方向上的底端)终止于不同的高度。模具120的这些部分之间的这种间隙或台阶可以设定为第一部件10的厚度和/或可以在Z轴方向上是可调的。模具120的任何部分122、125允许将第一部件10按压到第二部件20上、和/或将第一部件10和/或第二部件20相对于彼此固定。模具120的部分122、125的不同高度允许将延伸部125放置到第一部件10的侧面12和界面的开放端部。
模具120所需的按压力可以由柔性按压装置110实现、控制和/或支持。例如，柔性按压装置110可以用囊袋、活塞或弹簧的形式来实现，沿Z轴方向按压模具120，同时允许模具120或模具部分122、125沿相同方向实现特定运动。因此，可以针对第一部件10的厚度(高度)以及第一部件10和能量引导器30在熔化之前、期间和之后的变化的厚度来调整模具。
图2示意性地展示了另一示例性焊接设备100和待彼此焊接的热塑性部件10、20的截面。图2中与图1中所展示的相同或具有相同功能的特征用相同的附图标记表示，并且为了避免重复而省略对它们的描述。
图2的焊接设备100具有模具120，该模具形成为类似于图1的焊接设备100的延伸部125。代替具有模具120的按压在第一热塑性部件10上的单独部分122，图2的焊接设备100包括与模具120的部分122组合的焊接装置105。虽然焊接装置105和模具120在图2中被展示为分开的部件，但它们可以以集成方式构建，即具有与图1中的模具120一样的形式。在任何情况下，图2的焊接装置105可以被配置为将压力施加到第一热塑性部件10上，以固定第一部件10并且施加所需的焊接压力(聚合物分子的固结压力)。
延伸部125可以可选地在拐角处具有凹处126，该凹处被配置为布置在第一热塑性部件10的侧面12与第二热塑性部件20之间的区域中。此凹处126允许一定量的熔融热塑性聚合物流出第一部件10与第二部件20之间的界面，但进一步用圆角密封界面的开放端部。特别地，如果使用能量引导器30，则引入额外的热塑性聚合物，其中一小部分热塑性聚合物将在熔化时被挤出。这小部分热塑性材料可以用于正确地密封界面的开放端部。
应当理解，凹处126仅示例性地示出为延伸部125的倒角。凹处126可以具有任何形式，其允许在界面的开放端部以任何期望的形状形成焊缝密封。此外，如果延伸部125将在图2中进一步向下延伸(未展示出，因为第二部件20在第一部件的侧面12上延伸)，特别是如果第一部件10和第二部件20将具有相同或非常相似的长度(在Y轴方向上)、具有(几乎)齐平的侧面情况下，凹处126将仅布置在界面的开放端部的区域中。换言之，在凹处126的上方和下方，延伸部125的侧面(图2中的右侧)将齐平或成阶梯状(均未展示出)，这取决于第一部件10和第二部件20的相应侧面的位置。
焊接设备100的另一个可选元件可以是温度控制装置124。例如，如所展示的，温度控制装置124可以安装在模具120中，特别是安装在延伸部125中。温度控制装置124可以被配置为冷却或加热延伸部125的至少一部分。加热延伸部125允许促进界面的开放端部的密封以及促进第一热塑性部件10和/或第二热塑性部件20的材料中的均匀热分布。冷却延伸部125允许挤出的热塑性材料在第一热塑性部件10与第二热塑性部件20之间的界面的开放端部处受控固化。温度控制装置124可以通过加热/冷却流体和/或通过电加热/冷却元件来操作。
图3示意性地展示了示例性焊接设备100和待彼此焊接的热塑性部件10、20的沿移动方向(X轴方向)的截面。此示例性焊接设备100示出了也沿移动方向被分成多个模具部分127、128的模具120。相应的模具部分127、128可以被配置为在平行于由模具120施加到第一热塑性部件10和/或第二热塑性部件20上的压力的方向(Z轴方向)上相对于其他模具部分127、128移动。
这种分开的模具部分127、128允许模具适配第一热塑性部件10和/或第二热塑性部件20的任何不平坦。图3展示了第一热塑性部件10的台阶14或其他不平坦部分。如果模具120例如沿X轴方向(图3中向右)移动，则模具120的(多个)最右侧部分128可以在第一部件10中的台阶14处向上移动。第一部分10上的压力可以保持，从而均匀的压力分布是可能的。
如图3所展示的，柔性按压装置110被配置为补偿模具120的(多个)部分128的移动。例如，按压装置110至少在Z轴方向上提供一定的柔性，以允许模具120的部分128自由移动，同时在第一部件10上保持相同的每单位面积压力。当然，一旦模具120沿X轴方向进一步移动，模具120的部分127也是可沿Z轴方向移动的。
图3中示例性展示出的焊接设备100可以可选地包括移动装置130，该移动装置被配置为使焊接设备相对于第一热塑性部件10和第二热塑性部件20移动。例如，移动装置130可以简单地实施为沿导轨或其他导引件滚动的滚轮130。这允许实现长形焊缝并且进一步有助于提供紧凑的焊接设备100，特别是在移动方向(X轴方向)上较短的焊接设备100。
替代性地，移动装置130可以是使焊接设备100沿着任何编程路径移动的机械臂。因此，焊接设备100可以沿着第一热塑性部件10与第二热塑性部件20之间的界面、特别是沿着界面的开放端部移动。
图4展示了焊接热塑性部件10、20的方法的示例性流程图。可选地，在步骤205中，可以在第一热塑性部件10与第二热塑性部件20之间设置能量引导器。
在具有或不具有能量引导器的情况下，模具120在步骤210中均被按压到第一热塑性部件10和/或第二热塑性部件20上。这实现了两个部件的固定并且进一步允许施加所需的焊接/固结压力来将第一部件10和第二部件20的热塑性聚合物焊接一起。
在步骤215中，通过至少加热第一部件10和第二部件20的界面来实现焊接。这包括至少将第一部件10和第二部件20的界面区域的表面加热到热塑性材料(聚合物)的熔化温度，从而使聚合物分子可以彼此融合和结合(彼此互锁)。
该方法进一步包括在步骤220中将模具120的延伸部125放置成靠近第一部件10的侧面12。靠近第一部件10的侧面12放置的延伸部125允许通过避免、至少限制或控制从界面的开放端部挤出的熔融聚合物的量、通过在聚合物熔化时稳定第一部件10和/或第二部件20中的任何纤维、和/或通过用挤出的熔融热塑性材料密封这种纤维(在移出界面的开放端部或在界面的区域中变形时)来适当地密封界面的开放端部。应当理解，步骤210、215和220可以同时进行，或者步骤220可以在步骤215之前或之后进行。
在步骤230中，至少使模具120沿着第一热塑性部件10的边缘区域移动。同时，延伸部125可以沿着第一部件10的侧面12和沿着第二热塑性部件20滑动。因此，可以通过焊接设备100执行点焊，而步骤230中的移动允许提供长形焊缝。
以上对附图的描述应当理解为仅提供本发明的示例性实施例，而不应将本发明限制于此特定实施例。

Claims (13)

1.一种用于将热塑性部件彼此焊接的焊接设备(100)，所述焊接设备(100)包括：
焊接装置(105)，所述焊接装置被配置为至少熔化所述热塑性部件中的第一热塑性部件(10)与所述热塑性部件中的第二热塑性部件(20)之间的界面；以及
模具(120)，所述模具被配置为将所述第一热塑性部件(10)的边缘区域按压到所述第二热塑性部件(20)上，
其特征在于，
所述模具(120)具有延伸部(125)，所述延伸部在所述边缘区域处覆盖所述第一热塑性部件(10)的侧面(12)、并且接触所述第二热塑性部件(20)。
2.根据权利要求1所述的焊接设备(100)，进一步包括：
温度控制装置(124)，所述温度控制装置配置为冷却或加热所述延伸部(125)的至少一部分。
3.根据权利要求1所述的焊接设备(100)，进一步包括：
柔性按压装置(110)，所述柔性按压装置被配置为将所述模具(120)按压到所述第一热塑性部件和/或所述第二热塑性部件(10，20)上。
4.根据权利要求1至3之一所述的焊接设备(100)，其中，所述模具(120)被分成多个模具部分(122，125，127，128)，每个模具部分被配置为在平行于由所述模具(120)施加到所述第一热塑性部件和/或所述第二热塑性部件(10，20)上的压力的方向上相对于其他模具部分(122，125，127、128)移动。
5.根据权利要求4所述的焊接设备(100)，其中，所述模具(120)的所述延伸部(125)被分成所述多个模具部分(127、128)。
6.根据权利要求1至3之一所述的焊接设备(100)，其中，所述焊接装置(105)是超声焊接工具头。
7.根据权利要求1至3之一所述的焊接设备(100)，进一步包括：
移动装置(130)，所述移动装置被配置为使所述焊接设备(100)相对于所述第一热塑性部件和所述第二热塑性部件(10，20)移动。
8.根据权利要求1至3之一所述的焊接设备(100)，其中，所述模具(120)的所述延伸部(125)在拐角处具有凹处(126)，所述凹处被配置为布置在所述第一热塑性部件(10)的所述侧面(12)与所述第二热塑性部件(20)之间的区域中。
9.根据权利要求1至3之一所述的焊接设备(100)，其中，所述焊接装置(105)和所述模具(120)的第一部分(122)组合在集成装置中，并且其中，所述模具(120)的第二部分(125)形成或包括所述延伸部(125)。
10.一种将热塑性部件彼此焊接的方法，所述方法包括：
将模具(120)朝向所述热塑性部件中的第二热塑性部件(20)按压(210)到所述热塑性部件中的第一热塑性部件(10)的边缘区域上；以及
至少将所述第一热塑性部件与所述第二热塑性部件(10，20)之间的界面加热(215)到所述第一热塑性部件和所述第二热塑性部件的相应材料的熔化温度，
其特征为
将所述模具(120)的延伸部(125)放置(220)成在所述边缘区域处靠近所述第一热塑性部件(10)的侧面并且放置到所述第二热塑性部件(20)上。
11.根据权利要求10所述的方法，其中，所述加热(215)包括通过将来自超声焊接工具头的超声波至少施加到所述第一热塑性部件(10)中来加热所述第一热塑性部件和所述第二热塑性部件(10，20)。
12.根据权利要求10或11所述的方法，进一步包括：
在所述第一热塑性部件与所述第二热塑性部件(10，20)之间的界面处设置(205)能量引导器(30)。
13.根据权利要求10或11所述的方法，进一步包括：
至少使所述模具(120)沿着所述第一热塑性部件(10)的所述边缘区域移动(230)，其中，所述模具(120)的所述延伸部(125)的放置(220)包括使所述模具(120)的所述延伸部(125)沿着所述第一热塑性部件(10)的所述侧面(12)和沿着所述第二热塑性部件(20)滑动。
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