The improvement of the thermoplastic joints performance of Vibration Welding
The lateral reference material of related application
The U.S. Provisional Patent Application No.60/006 that on November 8th, 1996 filed an application, 334 are incorporated herein by reference, and the application need be from wherein benefiting.
The background of invention
The present invention relates to Vibration Welding, or more relate to the Vibration Welding of thermoplastic joints with refering in particular to.
In recent years, use thermoplastic to replace the demand of metal constantly to increase in automobile application such as air intake system.Estimate 2010, will produce 2,140 ten thousand various air with solder technology and suck part.The present invention relates to a kind of vibration welding method of improved thermoplastic joints, and the Vibration Welding product of producing in this way.
Thermoplastic, for example the Vibration Welding of nylon 6 and nylon 66 is well-known in the present technique field.See in " engineering of polymer and the science " 28,718 (1988) of V.K.Stokes " Vibration Welding of thermoplastic, first: the study of phenomenon of welding process "; In " engineering of polymer and the science " 28,728 (1988) of V.K.Stokes " Vibration Welding of thermoplastic, second portion: the analysis of welding process "; In " engineering of polymer and the science " 28,989 (1988) of V.K.Stokes " Vibration Welding of thermoplastic, third part: the intensity of polycarbonate butt seam welding "; " engineering of polymer and the science " 28 of V.K.Stokes, in 998 (1988) in people's such as " Vibration Welding of thermoplastic; the 5th part: the intensity of polymerization butenoic acid terephthalate, PEI and the butt seam welding of improvement polyphenylene oxide " and C.B.Bucknall " engineering of polymer and the science " 20,432 (1980) " hot plate welding of plastics: the influence factor of weld strength ".
Vibration Welding can be carried out like this, with its common interface vibration in the pressure lower edge of two parts, produces frictional heat, thereby with its surface melting be fused together.Vibration Welding be connect all size the out-of-shape part fast and inexpensive method.In the past, Vibration Welding has been used for low load field of bearings.In the application of automobile case, for example air sucks discharge, air cleaner shell block, and resonator, and the application that enlarges engineering plastics will make vehicle weight alleviate, and cost reduces.But, up to now, on these purposes, also can not obtain enough weld strengths.Welding result is extremely responsive to parameter homogeneity and slight vibration, and they may cause the marked change of welding quality.Vibration Welding parameter such as pressure, frequency, amplitude, vibration (welding) time, retention time and layer thickness all influence the tensile strength of welded joint.An object of the present invention is to provide the vibration welding method on a kind of fibre strengthening thermoplastic surface, the tensile strength ratio of the welded joint of gained is getable height before this.
United States Patent (USP) 4,844,320 think, weld strength is not subjected to above weld amplitude of certain level and the influence of weld interval.In traditional Vibration Welding, weld layer forms under 0.03 to 0.07 inch amplitude.In contrast, we find that weld amplitude and weld interval are extremely important indexs for improving weld strength.Vibration Welding of the present invention adopts the amplitude at least about 0.075 inch.Assert, the obtainable the maximum tensile strength of traditional Vibration Welding layer of strengthening the thermoplastic surface be corresponding thermoplastic material the formed weld layer of not strengthening surface about 80%.For glass fiber-reinforced thermoplastic, the reduction of this tensile strength is owing to the change in welds joint glass fibre orientation.According to the present invention, the obtainable the maximum tensile strength of Vibration Welding layer of strengthening the thermoplastic surface is up to 120% of the not weld layer that strengthening surface forms of corresponding thermoplastic material.This is because at least one surperficial fiber is caught to penetrate weld layer and another surface.This just provides additional, extra tensile strength for weld layer.
The explanation of invention
The invention provides and a kind ofly comprise the first surface of the fibre strengthening first thermoplastic composition and the joining method of second surface that comprises the second thermoplastic composition one, this method comprises makes first surface contact with second surface, and contacted first and second surfaces are carried out Vibration Welding, between first and second surfaces, form a weld layer, this weld layer is made of the fusions of the first and second thermoplastic compositions, it is characterized in that Vibration Welding is to carry out being enough to make fiber from first surface to penetrate under the condition in weld layer and the second surface.
The present invention also provides a kind of Vibration Welding product, it comprises a first surface that comprises the first fibre strengthening thermoplastic composition, comprise the second thermoplastic composition with one with the contacted second surface of first surface, and weld layer between first and second surfaces, it comprises the fusions of the first and second thermoplastic compositions, it is characterized in that, penetrate in weld layer and the second surface from the fiber of first surface.
The device of vibration welding technology and enforcement Vibration Welding is well-known in the present technique field, as what exemplified in this United States Patent (USP) 4,844,320 as a reference.The Vibration Welding of thermoplastic has four-stage, and promptly heat by friction at the interface, the lateral flow of unstable fusing and material, and the fusion zone is set up under steady-state condition; And since the vibration termination material flow and solidify in the instability of weld zone.Welding can be with carrying out with the standard vibration welding equipment that obtains the parameter condition of wanting required for the present invention through improving.Important parameters comprises pressure, amplitude, frequency, time welding interval and retention time.
Vibration welding machine can be buied from the Branson ultrasonic wave company of Kang Nadige state Danbury, as micro-vibration bonding machine and 90 serial VW/6 type vibration welding machines.But, because their specified amplitude range is 0.040 to 0.070 inch under the 240Hz output frequency, so must adjust.Vibration Welding can be undertaken by first thermoplastic surface is contacted under pressure with the second thermoplastic surface.At least one best two thermoplastic surface all is fiber strengthened.The surface that will weld is contacted each other, and at the interface that keeps under the predetermined pressure between two surfaces, for example it is positioned on the platform and is in by under cylinder or the hydraulic cylinder institute applied pressure.Make a surface do straight reciprocating motion then,, generate heat, melt two surfaces and the thermoplastic material on first and second surfaces is merged to cause friction with respect to another surface.Fiber before the welding in the fibre strengthening thermoplastic material is not have orientation substantially.In the vibration welding technology of prior art, contacted thermoplastic surface melting, fusion, formation one weld layer, still, the fiber that is in the weld layer only is on the direction on welding plane.Opposite with it, when carrying out Vibration Welding according to the present invention, the reinforcing fiber on a surface or two surfaces be pressed into its opposite contact surfaces in.The weld strength that is beyond one's reach before when weld layer cools off, just having obtained.
According to the present invention, two thermoplastic surfaces that can be soldered can be made of any compatible thermo-plastic polymeric material.Suitable thermo-plastic polymeric material comprises that (but being not limited only to this) is polyamide-based, polyesters, polycarbonate class, poly-maple class, polyimide class, polyamine lipid, polyethers, polyvinyls, and their mixture.Polyamide-based such as nylon 6 and nylon 66, for example Capron 8233G HS nylon 6 and Capron 5233G HS nylon 66 can be buied from the AlliedSignal company of New Jersey Morristown.Polyester material such as Petra polyethylene terephthalate is preferably also buied from AlliedSignal company.As long as aspect fusion, be compatible, also can use different thermoplastic surfacings.The thermoplastic surface has at least one to be fiber strengthened, preferably all strengthens for two.Suitable reinforcing fiber comprises (but being not limited only to this) such material, and it for example up to not softening under 400 ℃ the temperature, does not promptly lose its rigidity at the used representative temperature of injection moulding.Preferred fiber-reinforced material comprises as glass, carbon, silicon, metal, mineral matter, polymer fiber and their materials such as mixture.Best is glass fiber-reinforced.In a preferred embodiment, this fiber is a rigidity, and diameter is about 8 to 12 microns, about 9 to 11 microns better, preferably about 10 microns.Preferred fibre length is from about 120 microns to about 300 microns, better is from about 130 to about 250 microns, and preferably from about 140 to about 200 microns.In a preferred embodiment, the percentage by weight that this fiber accounts for the thermoplastic composition is about 6% to about 40%, and more better is that the percentage by weight that accounts for the thermoplastic composition is about 13% to 25%.
The displacement of the linear peak to peak that surface rubs on another surface or distance are vibration amplitudes.In most preferred embodiment, vibration amplitude is at least about 0.075.The vibration amplitude scope is from about 0.075 to about 0.15 inch preferably, and preferably from 0.075 to 0.090 inch.The specified output vibration frequency of above-mentioned amplitude is 240Hz.Under other vibration frequency, amplitude will change.For example, under the specified output vibration frequency of 120Hz, preferred amplitude range is certainly at least about 0.09 inch (0.13 inch is better) extremely about 0.16 inch, and preferably from about 0.135 inch to about 0.145 inch.For the professional person in the present technique field, can determine the amplitude under other frequency at an easy rate.
In a preferred embodiment, contact surface is in the Vibration Welding process under about pressure of 0.6 to about 1.5MPa perpendicular to the surface.Better pressure limit is about 0.6 to about 1.2MPa, and preferably about 0.7 to about 0.8MPa.The preferable range of time of vibration or fraction time is about 2 to 7 seconds, and more better is 4 seconds to 6 seconds.Retention time, or the preferable range of cool time is about 2 to about 8 seconds, more better is about 4 to about 5 seconds, after vibration stops during this period of time in, pressure still keeps.The preferable range of weld layer thickness is about 160 to about 400 microns, and more better is about 200 to about 350 microns, and preferably about 250 to about 330 microns.When carrying out Vibration Welding under these conditions, a part penetrates weld layer and facing surfaces from the fiber of strengthening surface.When two surfaces are when strengthening thermoplastic and constituting, all penetrate weld layer and facing surfaces from a part of fiber on each surface.In a preferred embodiment, the ratio of fiber that penetrates into the apparent surface from one or two strengthening surface that (according to tensile strength) is estimated is in about 2% to about 8% scope, and more better is about 4% to about 8%, preferably about 5% to 8%.The result of vibration welding process of the present invention is, a weld layer of strengthening thermoplastic surface and another thermoplastic surface has obtained higher the maximum tensile strength with being compared by the formed weld layer of not strengthening surface of corresponding thermoplastic material.The tensile strength of strengthening the Vibration Welding layer on thermoplastic surface is in by 85% of the formed weld layer of not strengthening surface of corresponding thermoplastic material at least, and preferably from about 85% to about 120% scope.Do not have special theory, just suppose that Vibration Welding parameter of the present invention can make fiber penetrate another surface from a strengthening surface.For example, the employing of pressure, and time of vibration and amplitude should be conductive, to push fiber to another from a melt surface.Weld layer thickness cross thin or the excessive fiber rotation space that may cause of fiber loading not enough, thereby the restriction fiber traverses into facing surfaces.
The following effect that does not have the example of restrictive, sense is explanation the present invention.Some element in the component of light sensitive layer composition changes in proportion or replaces for those skilled in the art is conspicuous, and within the scope of the present invention, this is all expressed appreciation.
Example one
The Capron 8233 G HS nylon 6 that will obtain from the AlliedSignal company of New Jersey Morristown and the particle of Capron 5233 G HS nylon 66 are made the piece of 3 " * 4 " * 1/4 " and 3 " * 4 " * 1/8 " with injection molding, and it contains the glass fiber-reinforced material that nominal percentage by weight is the 0-50% ratio.Same piece is used the following parameters Vibration Welding together with the micro-vibration welding machine or the 2400 serial welding machines of Branson ultrasonic wave company: maximum grip load: 4.5kN; Weld amplitude: 0.762 to 2.28mm (0.030 " to 0.090 "); Weld interval: 4-8 second; Specified welding frequency: 240Hz.Change welding parameter, be i.e. pressure (load), amplitude and time, make the tensile strength optimization of welds joint.Then only select the tensile strength that those obtained to be higher than the sample of not filling base material, study with institutional framework to the weld zone.Comprise the interface of weld zone and the details of fiber orientation in these analysis and research.Study the institutional framework of these samples and used light microscope, and what quantize that fibre length uses is image analyzer.
Weld zone glass fibre loading is analyzed
The nominal fiber loading of the Capron nylon 6 injection moulding parts of being studied is in the scope of 0 to 50% percentage by weight.But if fiber or nylon matrix are pushed open from the weld zone when weld layer forms, then the fiber loading of weld zone reality may change.Different with basic material whether for the fiber loading of determining weld layer excess enthalpy flow region are measured the percentage by weight of fiber by obtaining the weight difference of excessive part before and after the matrix pyrolysis.The result of 7 Capron 8233G HS nylon 6 samples of processing under different welding conditions is summarized in table 1.The result shows that the fiber loading of the various nylon 6 materials of being checked is approximately than low 0.5% to 1% percentage by weight of matrix composition.
For nylon 66, Capron 5233 G HS nylon 66 sample in measurements of the glass content in the weld zone burr.The results are shown in the table 2, show that nylon 66 hangs down 0.5% percentage by weight than matrix composition approximately at the fiber loading at weld zone burr place.The variation of these fiber contents is very little, and approaching with the certainty of measurement of fiber content.
The analysis of weld zone glass fibre length
Fracture in order to determine whether fiber in the weld zone has in a large number, carried out the fibre length analysis.The fibre length of the interior fiber of burr (reclaiming from the pyrolysis ash) is determined to measure with light microscope and image analyzer.Glass fiber sample is with 2,2, and 2-flurothyl (TFE) solvent extracts from ash and is dispersed on the slide.Each sample is according to 10 light micrographs, and 1000-2000 root fiber is counted and measured with image analyzer altogether.Table 3 provides its result.The analysis showed that the average fiber length of all samples is at 120 to 180 micrometer ranges.This is with the mean value of the sample fiber length of part measurement is suitable in addition in the weld zone from original molded stretching bar.In addition, with SEM studies show that of weld zone break surface there be not fractureing in a large number of fiber in the weld zone.
The analysis of weld zone glass fibre distribution of orientations
Glass fibre (GF) carries out with light microscope and SEM in the research of the fiber distribution (FOD) of weld metal zone.All prepare parallel and the cross section impenetrating thickness direction for each sample, and for light microscope research in preparation, carrying out metallurgical polishing.Express weld zone total FOD on every side than the light micrograph under the low range (25x and 50x), and the fiber of weld zone orientation.Light micrograph is respectively from the polishing section picked-up of nylon 6 samples of 6wt.%GF, 14wt.%GF, 25wt.%GF, 33wt.%GF and 50wt.%GF.Microphoto is expressed near being orientated with the fiber that departs from the weld zone.The apparent thickness of weld zone can directly directly be measured from the variation of FOD in the position shown in the microphoto in addition.We notice that in the sample of 14wt.% and 25wt.%GF, some fibre has the sign that significantly is orientated on the draw direction perpendicular to the welding plane.Be also noted that the orientation that shows on the molded panel of selecting to be used to weld with glass fibre at the strengthening effect under the best welding condition is irrelevant.
The tensile strength of welds joint
For every kind of Vibration Welding condition (that is: the pressure of setting, amplitude and weld interval), 10 samples of test under the ASTM of standard D638M-93 plastics tensile test rules.Concluded the result of welds joint tensile strength under best welding parameter condition in the table 4.The glass fibre loading is also studied effects of tensile strength.The result shows, the tensile strength of all welds joint samples all is higher than the nylon 6 do not strengthened.For the nylon 6 material of strengthening, the maximum tensile strength is 93.1MPa.This appears under the situation that the glass fibre loading is about 14wt.% and 25wt.%.By with tensile strength be the material compared of not strengthening of 79.3MPa, this makes the tensile strength of welds joint improve 17% in tensile strength maximum that reinforcing degree occurs.
Under same welding and intensified condition, the tensile strength of welding nylon 6 material shows high slightly (about 4%) than welding nylon 66.These data also show, at the interface, and glass fibre/nylon 66 compositions and matrix material approximate.The weld strength of glass-filled nylon 6 under the optimised welding procedure condition of being seen is higher, may have benefited from some factor.For nylon 6, to select under the same composition and welding parameter alternative condition, a certain proportion of glass fibre presents at the interface across the welding plane.The width of weld zone is about the 200-300 micron, and is suitable with the average length of fiber.This can make fiber have certain animal migration in welding process, moves on the direction beyond the main flow direction of resin, and promptly fiber is not to be completely restricted streamwise motion in narrow weld zone.Viewed weld zone thickness can be depicted as the function of fiber loading from the microphoto.We notice that weld zone thickness experiences maximum fiber-loaded under the situation of 14wt.% really.The position (14Wt.%H to 25Wt.% glass fibre (GF)) that this maximum occurs is peaked identical with the tensile strength curve.This shows that further weld zone thickness has positive impact to the tensile strength of welds joint.Be orientated welded specimen by preparation with respect to the fiber main flow, can carry out the research of the relation of welding performance and the glass fibre distribution of orientations in GF nylon 6 plates with different orientation.These data results show that at weld interface the fiber orientation that is obtained is irrelevant with the fiber main flow orientation in the matrix nylon 6 of contiguous weld zone in the weld zone.The data of the polyamides ammonium butt seam welding joint of straight-line oscillation welding show with disclosed data in the past to be compared, and the raising of tensile strength reaches 35%.
Table 1
The ratio of glass fibre in Capron 8233G HS (nylon 6) burr
Sample number | The percentage by weight of fiber (%) in the burr |
????1 | ????32.04 |
????2 | ????32.52 |
????3 | ????32.26 |
????4 | ????32.56 |
????5 | ????32.54 |
????6 | ????32.20 |
????7 | ????31.93 |
On average | ????32.29±0.25 |
Capron 8233G HS matrix | ????33.01±1.21 |
Table 2
The ratio of glass fibre in Capron 5233G HS (nylon 66) burr
The sample sign | The percentage by weight of glass fibre (%) in the burr | The percentage by weight of glass fibre (%) in the matrix |
5233GHS | ?33.48 | ?33.94 |
Table 3
Capron 8233G HS (nylon 6) fibre length analysis
Sample number | Fiber number | The average length of fiber (micron) |
?1 | ????1775 | ?124.7 |
?2 | ????1838 | ?131.8 |
?3 | ????1106 | ?151.9 |
?4 | ????1182 | ?147.7 |
?5 | ????1018 | ?167.8 |
?6 | ????1381 | ?145.9 |
?7 | ????834 | ?180.25 |
Capron 8233G HS matrix | ????1374 | ?133.7 |
Table 4
The percentage by weight of glass fibre (%) | Trade name | Tensile strength under best welding condition (MPa) |
????0 | ????Capron8202G?HS | ????79.3 |
????6 | ????Capron8230G?HS | ????83.1 |
????14 | ????Capron8231G?HS | ????90.7 |
????25 | ????Capron8232G?HS | ????90.2 |
????33 | ????Capron8233G?HS | ????85.2 |
????50 | ????Capron8235G?HS | ????80.5 |