CN116494540A - 用于表面结构化的方法 - Google Patents

用于表面结构化的方法 Download PDF

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Publication number
CN116494540A
CN116494540A CN202310051588.2A CN202310051588A CN116494540A CN 116494540 A CN116494540 A CN 116494540A CN 202310051588 A CN202310051588 A CN 202310051588A CN 116494540 A CN116494540 A CN 116494540A
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China
Prior art keywords
component
filler sheet
welding
filler
structuring
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Pending
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CN202310051588.2A
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English (en)
Inventor
加利纳·贡恰罗娃
阿列克谢·维奇尼亚科夫
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Airbus Operations GmbH
Airbus Operations SAS
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Airbus Operations GmbH
Airbus Operations SAS
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Publication of CN116494540A publication Critical patent/CN116494540A/zh
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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
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
    • B29C66/022—Mechanical pre-treatments, e.g. reshaping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/04—Dielectric heating, e.g. high-frequency welding, i.e. radio frequency welding of plastic materials having dielectric properties, e.g. PVC
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1403—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the type of electromagnetic or particle radiation
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    • B29C66/0222—Mechanical pre-treatments, e.g. reshaping without removal of material, e.g. cleaning by air blowing or using brushes
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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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    • 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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    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
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    • B29C66/30221—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 said melt initiators being point-like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明涉及用于表面结构化的方法。为了允许改进零部件接合的方法，本发明提出一种用于生产具有适于将两个零部件进行塑性焊接或粘附剂粘接的表面的部件的方法。作为接合前的准备步骤，将包括热塑性材料或粘附剂的填料片材布置在第一部件的第一表面上，并将结构化工具布置在填料片材上。向结构化工具施加机械力并向填料片材施加热，使得填料片材附接至第一部件的第一表面，并且使得结构化工具部分地嵌入填料片材中。随后从填料片材移除结构化工具，以在填料片材的外表面中产生多个凸出部。在表面结构化之后，第一和第二部件使用超声焊接或红外线焊接或感应焊接或激光束焊接或传导焊接和共同固结或任何其他焊接技术而接合或者使用粘附剂粘接而接合。

Description

用于表面结构化的方法
背景技术
本发明涉及用于生产具有适于进行塑性焊接或粘附剂粘接的表面的零部件的方法。该方法可以用于制造由两个或更多个零部件构成的组件，所述两个或更多个零部件接合在一起，例如通过超声焊接或粘附剂粘接而接合在一起。该方法可以应用于加强元件，比如飞行器机身的纵梁、壳体或夹子。
焊接描述了下述过程：在该过程中，两个或更多个零部件通过使零部件的基底材料熔融并使零部件之间基底材料融合而接合。可以使用各种方法将能量供给至在零部件之间的交界面区域，以使交界面区域附近的基底材料熔融。例如，呈超声波形式的能量用于超声焊接，并且激光用于激光焊接。
超声焊接能够用于焊接包括复合材料在内的热塑性部件。US 4618516公开了一种通过超声能量将两个热塑性部件沿着各自的相对的表面接合的方法，其中，一个部件表面设置有能量导向部，而另一部件表面设置有粗糙纹理表面。在工件之间施加压缩力，并且接着通过超声变幅杆、也称为超声波发生器将超声能量施加至工件。超声能量在热塑性部件中的耗散在工件之间的交界面处产生了熔融的热塑性材料。在预定的时间间隔后，移除超声能量，这使得熔融的热塑性材料固化，并且因此在工件之间提供有融合接合部。
能量导向部用于将能量集中在焊接区域内，并使得热塑性材料软化和熔融所需的能量的量减少，并增加接合部或焊接部的强度。在US 4618516中，能量导向部由凸出部形成，凸出部例如是锥形部或脊状部，其形成在工件中的一者的基底材料中并且从一个工件的表面突出并接触另一部件的粗糙表面。
发明内容
因此，本发明的目的是能够实现对用于通过焊接来接合两个或更多个部件的方法的改进，并提高焊接质量和可靠性。
这由独立权利要求的主题来提供。进一步的改进是从属权利要求的主题。
根据本发明，一种用于生产具有适于将两个或者更多个零部件接合的表面的零部件的方法，该表面适于例如通过塑性焊接、超声焊接或粘附剂粘接而将所述两个或者更多个零部件接合。该方法包括：提供包括第一表面的第一部件；在第一表面上布置包括塑性材料的填料片材；以及在填料片材上布置结构化工具。向结构化工具施加机械力，并且向填料片材施加热，使得填料片材附接至第一部件的第一表面，并且使得结构化工具(4)部分地嵌入填料片材中。从填料片材中移除结构化工具，并且在填料片材中产生包括多个凸出部的外表面。
该方法可以用于提供表面结构化，并且用作下述步骤之前的准备步骤：将具有包括多个凸出部的外表面的部件接合至一个或更多个其它部件或零件。
在表面结构化后，第一部件和第二部件使用超声焊接或红外焊接或感应焊接或激光束焊接或传导焊接及共同固结或任何其他焊接技术而接合，或者使用粘附剂粘接而接合。
施加至结构化工具的机械力在结构化工具与第一表面之间提供压缩力，使得结构化工具被迫压到填料片材中，并且使得结构化工具随着填料片材的热塑性材料在热的施加下熔融而变得部分地嵌入在填料片材中。随后，移去热和机械力，从而允许热塑性填料片材冷却并重新固化。此后，将结构化工具从附接至第一部件的固体填料片材中移除，以在附接至第一部件的第一表面的填料片材的其余部分的外表面中产生多个凸出部。
第一部件被提供了适于超声焊接的表面结构化，这是由于在填料片材外表面形成的凸出部在后续的部件与另一部件的焊接期间提供能量导向部。能量导向部形成在填料片材的表面中，而不是直接形成在第一部件的本体或基底材料中。这简化了待接合部件的制造，并且还使得该方法能够用于接合由更大范围的材料形成的部件，并且还能够用于接合不同材料的部件。由于在两个部件之间的交界面处形成的尺寸变化或间隙可以通过填料片材的熔融的材料来补偿，所以使用附加的填料片材还能够提高焊接质量。
在实施方式中，该方法还包括：将第二部件布置在多个凸出部上，并通过焊接而将第一部件和第二部件接合以形成组件。在组件中，第一部件和第二部件通过焊接技术而接合。典型地，在第一部件与第二部件之间施加压缩力，使得第二部件的表面与形成在已经接合至第一部件的填料片材的外表面中的凸出部接触。例如，第一部件和第二部件可以相对于彼此被夹紧。如上所述，焊接是这样一种过程：向部件施加能量，这使得第一部件和第二部件的材料至少在紧邻于接合交界面的区域中熔融。这导致第一部件与第二部件之间的基底材料融合。然后移除能量，使得部件冷却，熔融的材料固化，并且在第一部件与第二部件之间形成焊接接合部。因此，本发明还提供了一种焊接方法。
在示例中，焊接过程是超声焊接。例如，通过超声波发生器将具有16kHz至60kHz范围内的频率和10μm至200μm范围内的振幅的超声波在预定的时间间隔内、例如在几秒钟的时间间隔内提供至部件和填料片材，在此期间，填料片材和第一部件和第二部件的相邻区域熔融，从而导致基底材料融合。然后关断超声波发生器，从而允许部件和通过第一部件和第二部件的基材的融合而形成的接合部冷却并固化，因此在第一部件与第二部件之间产生焊接接合部。
热塑性聚合物无论是在无填充条件下还是被填充有纤维增强材料，其超声焊接都是基于这样的原理：当具有超声波频率的声波穿过交界面进入到相邻部件中时，该声波在内部传播的动能将部分耗散为热能。该热能将使靠近于交界面的区域中的热塑性聚合物熔融，从而导致两个部件的基质即热塑性材料的大分子扩散，以在冷却后在两个部件之间形成焊接接合部。由填料片材中的凸出部提供的能量导向部用于使交界面处的热产生局部化。焊接过程可以静态或连续地进行。
本文中描述的方法也可以用于将多于两个的部件接合以形成组件。焊接是一种局部接合方法，因此在组件包括多于两个部件的实施方式中，例如通过重复该方法或重复该焊接过程而顺序地形成每个焊接接合部。
然而，焊接过程不限于超声焊接，也可以使用其他类型的焊接过程，例如红外焊接、感应焊接、激光束焊接或传导焊接和共固结过程。焊接过程的类型可以根据填料片材的材料和待接合的部件的基体材料来选择。
此外，该方法还可以用于生产具有结构化表面的部件，该结构化表面具有多个凸出部，用于在粘合剂粘接过程中使用。通过这种方法可以在相接合的两个零部件中的一者的表面上产生和构造粘接层。本发明不限于热塑性材料的接合，而是可以应用于所有种类的塑料材料和金属材料。所应用的层应该能够进行塑性成形并与主要接合零部件接合。
在一些实施方式中，填料片材包括热塑性材料。填料片材的热塑性材料可以具有至少120℃的熔融温度。填料片材可以不含纤维或其他填充材料，并且可以仅由热塑性材料组成。替代性地，除了热塑性材料之外，填料片材可以包括比如纤维的填料。纤维可以是碳纤维、玻璃纤维、陶瓷纤维或金属纤维。可以使用连续的、长的或短的纤维。填料片材可以包括各种类型的热塑性材料，包括聚芳醚酮(LM PAEK)、聚醚酮酮(PEKK)、聚醚醚酮(PEEK)、聚醚酰亚胺(PEI)、聚酰胺(PA)、聚苯硫醚(PPS)、聚丁烯(PB)、聚酯嵌段共聚物(PBC)、聚氯乙烯(PV)和聚碳酸酯(PC)。此外，不同种类的粘接材料可以用作填充材料，例如热固性树脂，如环氧树脂。
在一些实施方式中，填料片材是平面的连续片材。在一些实施方式中，填料片材包括孔或穿孔。在一些实施方式中，填料片材在结构上是一体的且自支撑的，并且是非原位形成的。这种类型的板材容易处理。在一些实施方式中，填料的材料例如以液体形式施用至待接合的区域，并且片材在部件的第一表面上原位形成。
在一些实施方式中，第一部件和/或第二部件包括塑料材料，比如热塑性材料或热固性材料。在一些实施方式中，第一部件和/或第二部件包括金属或合金。第一部件和/或第二部件可以包括未增强的和增强的塑料或金属材料。在一些实施方式中，第一部件和/或第二部件包括复合材料。复合材料可以包括增强材料比如纤维或颗粒，以及由热塑性材料形成的基质。例如，复合材料可以是纤维增强复合材料，其中热塑性塑料提供基质。纤维可以是石墨、石墨烯、碳纤维、玻璃或陶瓷纤维或颗粒。此外，可以应用生物源纤维。可以使用连续的、长的或短的纤维。在一些实施方式中，第一部件和/或第二部件可以是层压材料。此外，可以应用经过再循环、降级循环或再利用后的纤维或颗粒。
第一部件和/或第二部件的热塑性材料可以具有至少120℃的熔融温度。第一部件和/或第二部件的热塑性材料可以是LM PAEK、PEKK、PEEK、PEI、PA、PPS、PB、PBC、PV和PC。热固性材料可以与环氧树脂基质一起施用。此外，其他基质材料也是合适的，如生物源基质。
在一些实施方式中，填料片材包括与第一部件和/或第二部件相同的热塑性材料。这是有益的，因为填料片材和第一部件和/或第二部件的热塑性材料在相同的温度下熔融，并且使得能够在填料片材与第一部件和/或第二部件之间能够进行良好的大分子扩散。由于促进了融合，这对于提供高焊接质量是有益的。
在一些实施方式中，第一部件和第二部件中的一者或两者可以由除了热塑性塑料之外的材料形成。例如，第一部件和第二部件中的一者或两者可以包括热固性材料，或者可以由合金或金属形成，或者可以包括包含金属层和非金属层的层压材料。例如，层压材料可以是纤维金属层压材料，例如玻璃层压铝增强环氧树脂(GLARE)。
填料片材和/或结构化工具可以局部地应用于第一部件的第一表面的接合区域或焊接区域。因此，凸出部仅形成在第一部件的将要与第二部件接合的区域上。接合区域之外的第一表面的其余部分保持没有填料片材和结构化部分。
结构化工具可以具有这样的尺寸：使得在将结构化工具从填料片材中移除之后，在外表面中形成的凸出部具有亚毫米范围内的尺寸、即小于2mm、优选地小于1mm的尺寸。例如，凸出部可以具有基本平行于第一表面的尺寸或基本垂直于第一表面的尺寸，其小于2mm，优选地小于1mm。凸出部之间的间距，即凸出部之间形成的凹入部的尺寸，也可以在亚毫米范围内。凸出部的尺寸和凸出部之间的间距例如可以根据超声焊接中使用的波长来选择。
为了将填料片材附接至第一部件的第一表面，施加热。热可以使用外部热源或能源而施加至填料片材。例如用于红外加热的外部红外源、卤素灯、传导加热、感应加热和/或激光加热。这种加热也可以局部地应用于第一部件，例如局部地应用于待与另一部件接合的区域，使得接合区域之外的区域不直接受热。第一部件的受热的面积可以大致限制在填料片材的侧向范围内。这对于下述方面是有益的：避免部件在焊接区域以外发生熔融，这种熔融可能导致变形；以及避免部件的尺寸或性能发生不期望的变化。
在一些实施方式中，结构化工具包括金属部分，比如金属网，例如钢网、钛网、铜网、镁网，或者包括剥离层。该网可以由编织网、波形网、扩张网、切割网或冲压网形成。在一些实施方式中，结构化工具包括金属织物、玻璃纤维织物或陶瓷纤维织物。结构化工具还可以包括涂层，该涂层用于使结构化工具能够更容易地从填料片材上移除，即使用较小的力从填料片材上移除。
在一个实施方式中，钢网与PEKK热塑性材料结合地用于填料片材，并且卤素灯用于加热填料片材。第一部分和第二部分包括纤维增强热塑性复合材料，例如碳纤维增强热塑性复合材料。
部件和由该部件与一个或更多个其他部件构成的组件可以是飞行器的一部分，例如是飞行器或飞行器机身的结构部分，比如加强元件，例如纵梁、壳体或夹子。
在一些实施方式中，部件和由该部件与一个或更多个其他部件构成的组件可以是无人驾驶飞机或直升机或火箭或卫星或机动车辆例如客车或货车的一部分。
附图说明
参照下面列出的示意性附图对本发明的实施方式进行了更详细的描述。
图1图示了将填料片材和结构化工具应用于部件。
图2图示了压力板和热源的应用。
图3图示了将结构化工具部分地嵌入填料片材。
图4图示了移除压力板和热源后的部件。
图5图示了移除结构化部分后的部件。
图6图示了两个部件之间的焊接区域的放大视图。
图7图示了用于超声焊接的设备。
图8图示了飞行器。
具体实施方式
现在将参照图1至图5对用于制造具有适于超声焊接的表面的部件的方法进行描述。
图1图示了具有第一表面2的部件1的示意图。在图1至图5中，图示了第一表面2的将接合至另一部件的部分的视图，即示出了部件1的接合区域或焊接区域5。在部件1的第一表面2上布置有包括热塑性材料的填料片材3，并且在填料片材3上布置有结构化工具4。
部件1包括纤维增强复合材料，其中基质包括热塑性材料。在其他实施方式中，第一部件可以由没有增强物的热塑性材料形成，或者第一部件可以包括具有颗粒或细丝增强物的复合材料。例如，热塑性塑料可以是PEKK，并且纤维可以是碳纤维。
填料片材3可以包括热塑性材料的平面片材，或者可以包括一个或更多个穿孔。在一些实施方式中，可以将两个或更多填料片材堆叠到部件1的第一表面2上，并将结构化工具4放置到最外层上。填料片材3的热塑性材料以及第一部件的热塑性材料可以具有至少120℃的熔融温度。填料片材3的热塑性材料和部件1的热塑性材料可以是相同的，例如为PEKK。填料片材3可以没有纤维或其他填充材料，并且可以仅由热塑性材料组成。替代性地，除了热塑性材料之外，填料片材3可以包括填料比如纤维。纤维可以是碳纤维、玻璃纤维或陶瓷纤维。可以使用连续的纤维、长的纤维或短的纤维。
结构化工具4由热稳定性比填料片材3的热塑性材料的熔点更高的材料形成。结构化工具4可以包括金属网，例如钢网，因而在图1至图5的横截面视图中，可以看到网的多个基本圆形的细丝15的横截面。该网可以是钢网，并且可以使用各种方法制造，例如编织、冲压或切割。在其他实施方式中，网的细丝不具有圆形横截面，而是例如可以是方形、矩形、六边形或椭圆形。在一些实施方式中，结构化工具4由编织纤维形成，例如玻璃纤维或陶瓷纤维。
结构化工具4有利地由不容易焊接至部件1或填料片材3以使其能够被移除的材料形成。这可以通过结构化工具4的结构以及/或者通过结构化工具4的低粘附特性即排斥特性来实现，这允许使用较小的力来移除结构化工具4，例如通过剥离来移除结构化工具4，并且优选地不会损坏待接合的部件1。
参照图2，机械力施加至结构化工具4，如箭头6示意性所示，使得在结构化工具4与部件1之间存在压缩力。在结构化工具4上与填料片材3相反的一侧上可以定位有板7，并且板7用于向结构化工具4施加机械压力。如图2中箭头9示意性所图示，从外部热源8向填料片材3施加能量，使得填料片材3软化或熔融并允许其附接至部件1的第一表面2，并且使得结构化工具4被推到填料片材3中并部分地嵌入填料片材3中，如图3所图示。例如，卤素灯可以用作为外部热源8。卤素灯在PEKK用作填料片材3和第一部件1的热塑性塑料的实施方式中是有益的。
如图4所图示，然后移除热和机械力，从而允许填料片材3的热塑性材料固化。填料片材3现在附接至部件1的第一表面2，并且可以焊接至第一表面2，这取决于填料片材3的材料和第一表面2的材料以及所施加的热。结构化工具4的一部分保持嵌入填料片材3中，并且一部分从填料片材3突出。
如图5所图示，然后将结构化工具4从装置中移除。在移除结构化工具4之后，填料片材3具有外表面10，该外表面10的表面轮廓包括由凹入部12分开的多个凸出部11。凸出部11和/或凹入部12的尺寸可以在亚毫米范围内。凸出部11可以具有亚毫米范围的尺寸，例如小于1m的尺寸，例如小于0.9mm或小于0.7mm或小于0.5mm的尺寸。这些尺寸可以在一个维度上或在两个维度上，例如平行于第一表面2的维度和垂直于第一表面2的维度。凸出部11可以彼此间隔开小于1mm，例如小于0.9mm或小于0.7mm或小于0.5mm。
当结构化工具4移除时，在填料片材3与结构化工具4之间的交界面处或者在填料片材3内可能形成裂缝，使得外表面10的表面轮廓不一定精确地对应于结构化工具4的嵌入填料片材3中的轮廓。外表面10可以具有更有角度且不规则的形状，凸出部11具有更尖的梢或峰。凸出部11可以具有梢，梢可以具有金字塔或细长边缘的形式。如参照图6和图7所示，在填料片材3中形成的凸出部11在随后的焊接过程中提供能量导向部。对于超声焊接，具有尖梢的凸出部11尤其适合用作为能量导向部。
通过将填料片材3结构化，于焊接之前在待焊接的部件中的一者上直接制造能量导向部。使用下述表面结构化工艺：其中，在附加的聚合物部件即结构化填料片材3上形成表面轮廓，该填料片材3可以具有或不具有纤维增强。该表面结构化过程用于准备和调整接合表面5，以将表面5焊接至另一零件，例如通过超声波和超声焊接而焊接至另一零件。
填料片材3可以由与待接合的部件中的一者或两者相同的聚合物即热塑性材料形成，或者在复合材料的情况下，填料片材3可以与复合部件的热塑性部分、典型地即基质具有相同的成分。包括多个凸出部11的结构化表面轮廓10提供了能量导向部的阵列，该阵列在超声焊接中用于加工辅助。填料片材3在焊接之前在部分固结之后仅施用在部件的应当进行焊接的表面2处。
填料片材3可以通过局部焊接例如红外焊接、感应焊接或传导焊接而施用至表面2，并且然后，移除结构化工具4以提供具有亚毫米级结构的表面轮廓10。在一些实施方式中，表面轮廓10可以具有金字塔或锯齿状形状。使用结构化工具4形成能量导向部具有以下优势：由于能量导向部的尺寸、形状和分布而提高焊接的过程能力和可靠性并且由于易于处理而产生经济优势。
现在将参照图6和图7描述使用具有结构化填料片材3及其多个凸出部11的部件1进行焊接的方法。
图6图示了在焊接过程中使用具有结构化填充材料层10的部件1以形成组件的示意图，该结构化填充材料层10布置在部件1的接合区域5处。另一部件13的表面14定位在填料片材3的多个凸出部11上，并且部件1、部件13通过焊接而彼此连接，如图6中由箭头16示意性所图示。
由填料片材3提供的附加填充材料可以用于补偿焊接期间的公差，以及通过利用部件1、部件13的基质材料充实接合区域来提高焊接接头的性能。
图7图示了用于对部件1、部件13进行超声焊接的设备20的示意图。为了将第一部件1和第二部件13彼此焊接，使用能量源。待连接的部件1、部件13也可以称为粘附体。结构化填料片材3在部件1与部件13之间的交界面23处定位在部件1、部件13将进行接合的位置处。第一部件1和第二部件13可以通过砧座24上的夹具21、22而保持就位，并且如箭头25所示的那样施用机械压力。第一部件1的第一表面2的其余部分和第二部件13的接合表面14保持成未由结构化填料片材3覆盖。
填料片材3的结构化表面10具有表面轮廓，该表面轮廓具有由凹入部12隔开的多个凸出部11。凸出部11和/或凹入部12可以规则或不规则地排列。部件13的表面14与填料片材3的凸出部11直接接触。凸出部11作为能量导向部，并且用于将超声能量从超声波发生器26向第一部件的第一表面2与第二部件13的第一表面14之间的接触区域导向。凸出部11用作多个分布式超声源，并在部件1与部件13之间的接合区域上提供更规律的超声能量耗散。
图7图示了一个超声波发生器的示例。超声波发生器26包括气动压力机27、变频器28、压电转换器29、增压器30以及超声波发生器梢部31。在图7所图示的实施方式中，使超声波发生器26与待焊接的部件中的一者接触、即与部件13接触。如图7中由箭头33示意性所示，超声波发生器26在部件1、部件13上施加静压力以及高频(20kHz)低振幅(10μm至50μm)的横向机械振动。由摩擦和粘弹性加热相结合产生热。由于与纤维增强部件1、部件13相比能量导向部的刚度较低，因此由较高的循环应变而引起能量导向部即填料片材3的凸出部11的熔融。超声能量被引入到部件13、填料片材3和部件1中，由此填料片材3中的凸出部11用作能量导向部并分配超声能量，以使得填料片材3的热塑性材料和部件1、部件13的热塑性材料在部件1与部件13之间的交界面的区域中熔融。
因此，不仅填料片材3的其余部分及其结构化表面10熔融，而且部件1和13的邻近于接触界面的区域熔融，从而允许第一部件1和第二部件13的材料熔融，即允许纤维34和热塑性基质35熔融，如图7示意性所图示。因此，在去除超声能量后，热塑性材料冷却并固化，从而在部件1与部件13之间产生焊接接合部32。
在实施方式中，部件1、部件13是飞行器100的一部分，如图8中所图示。例如，焊接组件可以用作机身101的一部分。在一些实施方式中，部件1、部件13中的一者或两者可以是加固或加强部件，例如纵梁101、壳体或夹子。
附图标记列表：
1 部件
2 第一表面
3 填料片材
4 结构化部分
5 接合区域
6 箭头
7 板
8 热源
9 箭头
10 外表面
11 凸出部
12 凹入部
13 部件
14 表面
15 细丝
16 箭头
20 设备
21 夹具
22 夹具
24 砧座
25 箭头
26 超声波发生器
27 气动压力机
28 变频器
29 压电转换器
30 增压器
31 超声波发生器梢部
32 焊接接合部
33 箭头
34 纤维
35 热塑性基质
100 飞行器
101 纵梁

Claims (15)

1.一种用于生产具有适于将两个或更多个零部件接合的表面的部件的方法，所述方法包括：
提供包括第一表面(2)的第一部件(1)；
将包括热塑性材料的填料片材(3)布置在所述第一表面(2)上；
将结构化工具(4)布置在所述填料片材(3)上；
向所述结构化工具(4)施用机械力并且向所述填料片材(3)施加热，使得所述填料片材(3)附接至所述第一部件(1)的所述第一表面(2)，并且使得所述结构化工具(4)部分地嵌入所述填料片材(3)中；
从所述填料片材(3)移除所述结构化工具(4)并且在所述填料片材(3)中产生包括多个凸出部(11)的外表面(10)。
2.根据权利要求1所述的方法，还包括：
将第二部件(13)布置在所述多个所述凸出部(11)上，以及
通过接合而将所述第一部件(1)和所述第二部件(13)接合以形成组件。
3.根据权利要求2所述的方法，其中，所述第一部件(1)和所述第二部件(13)使用焊接技术或粘附剂粘接而接合，所述焊接技术例如为超声焊接或红外线焊接或感应焊接或激光束焊接或传导焊接及共同固结。
4.根据权利要求1至3中的任一项所述的方法，其中，所述填料片材(3)的所述热塑性材料包括由LM PAEK、PEKK、PEEK、PEI、PA、PPS、PB、PBC、PV和PC组成的组中的至少一者，并且/或者，所述填料片材(3)包括粘附性材料。
5.根据权利要求1至4中的任一项所述的方法，其中，所述第一部件(1)和/或所述第二部件(13)包括增强的或未增强的塑料材料或金属材料。
6.根据权利要求5所述的方法，其中，所述第一部件(1)和/或所述第二部件(13)包括增强的或未增强的塑料材料或金属材料，由此所述塑料材料或所述金属材料形成基质。
7.根据权利要求5或6所述的方法，其中，所述第一部件(1)和/或所述第二部件(13)包括热塑性材料，比如由LM PAEK、PEKK、PEEK、PEI、PA、PPS、PB、PBC、PV和PC组成的组中的至少一者。
8.根据权利要求7所述的方法，其中，所述填料片材(3)包括与所述第一部件(1)和/或所述第二部件(13)相同的热塑性材料。
9.根据权利要求1至4中的任一项所述的方法，其中，所述第一部件(1)和/或所述第二部件(13)包括热固性材料，或者由金属形成，或者由合金形成，或者由包括金属层和非金属层的层压材料形成。
10.根据权利要求1至9中的任一项所述的方法，其中，所述填料片材(3)和所述结构化工具(4)局部地应用于所述第一部件(1)的所述第一表面(2)的接合区域(5)。
11.根据权利要求10所述的方法，其中，热局部地施加至所述第一部件(1)的所述第一表面(2)的所述接合区域(5)。
12.根据权利要求1至11中的任一项所述的方法，其中，所述凸出部(11)具有基本平行于所述第一表面的或基本垂直于所述第一表面的尺寸，所述尺寸小于2mm。
13.根据权利要求1至12中的任一项所述的方法，其中，热通过红外加热、卤素灯、传导加热、感应加热和/或激光加热而施加至所述填料片材(3)。
14.根据权利要求1至13中的任一项所述的方法，其中，所述结构化工具(4)包括金属部分，例如金属网或金属织物，或者包括玻璃纤维织物或陶瓷纤维织物。
15.根据权利要求1至14中的任一项所述的方法，其中，所述第一部件(1)和/或所述第二部件(13)是飞行器、无人驾驶飞机或直升机或火箭或卫星或机动车辆的结构零部件。
CN202310051588.2A 2022-01-26 2023-01-28 用于表面结构化的方法 Pending CN116494540A (zh)

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US4618516A (en) 1985-09-12 1986-10-21 Branson Ultrasonics Corporation Ultrasonic welding of thermoplastic workpieces
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