CN1309549C - 聚合物或聚合物复合物组件的焊接技术 - Google Patents

聚合物或聚合物复合物组件的焊接技术 Download PDF

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Publication number
CN1309549C
CN1309549C CNB028150732A CN02815073A CN1309549C CN 1309549 C CN1309549 C CN 1309549C CN B028150732 A CNB028150732 A CN B028150732A CN 02815073 A CN02815073 A CN 02815073A CN 1309549 C CN1309549 C CN 1309549C
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polymer
thermoplastic
thermosetting polymer
thermosetting
assembly
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Expired - Fee Related
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CN1537047A (zh
Inventor
M·豪
A·比哈格
Q·袁
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Advanced Composite Structures Australia Pty Ltd
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Advanced Composite Structures Ltd
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    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/12Bonding of a preformed macromolecular material to the same or other solid material such as metal, glass, leather, e.g. using adhesives
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/002Joining methods not otherwise provided for
    • B29C65/006Diffusion joining
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/481Non-reactive adhesives, e.g. physically hardening adhesives
    • B29C65/4815Hot melt adhesives, e.g. thermoplastic adhesives
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/03After-treatments in the joint area
    • B29C66/034Thermal after-treatments
    • B29C66/0342Cooling, e.g. transporting through welding and cooling zone
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11Joint 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
    • B29C66/112Single lapped joints
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11Joint 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
    • B29C66/112Single lapped joints
    • B29C66/1122Single lap to lap joints, i.e. overlap joints
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/13Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/131Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/341Measures for intermixing the material of the joint interlayer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/40General 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
    • B29C66/41Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43Joining a relatively small portion of the surface of said articles
    • B29C66/434Joining substantially flat articles for forming corner connections, fork connections or cross connections
    • B29C66/4344Joining substantially flat articles for forming fork connections, e.g. for making Y-shaped pieces
    • B29C66/43441Joining substantially flat articles for forming fork connections, e.g. for making Y-shaped pieces with two right angles, e.g. for making T-shaped pieces, H-shaped pieces
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/40General 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
    • B29C66/47Joining single elements to sheets, plates or other substantially flat surfaces
    • B29C66/474Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially non-flat
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/50General 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
    • B29C66/51Joining 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
    • B29C66/52Joining tubular articles, bars or profiled elements
    • B29C66/524Joining profiled elements
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General 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
    • B29C66/72General 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
    • B29C66/721Fibre-reinforced materials
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General 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
    • B29C66/73General 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
    • B29C66/731General 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 intensive physical properties of the material of the parts to be joined
    • B29C66/7311Thermal properties
    • B29C66/73115Melting point
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General 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
    • B29C66/73General 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
    • B29C66/731General 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 intensive physical properties of the material of the parts to be joined
    • B29C66/7311Thermal properties
    • B29C66/73117Tg, i.e. glass transition temperature
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General 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
    • B29C66/73General 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
    • B29C66/737General 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 state of the material of the parts to be joined
    • B29C66/7375General 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 state of the material of the parts to be joined uncured, partially cured or fully cured
    • B29C66/73751General 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 state of the material of the parts to be joined uncured, partially cured or fully cured the to-be-joined area of at least one of the parts to be joined being uncured, i.e. non cross-linked, non vulcanized
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General 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
    • B29C66/73General 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
    • B29C66/737General 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 state of the material of the parts to be joined
    • B29C66/7377General 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 state of the material of the parts to be joined amorphous, semi-crystalline or crystalline
    • B29C66/73773General 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 state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being semi-crystalline
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General 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
    • B29C66/73General 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
    • B29C66/737General 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 state of the material of the parts to be joined
    • B29C66/7377General 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 state of the material of the parts to be joined amorphous, semi-crystalline or crystalline
    • B29C66/73775General 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 state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being crystalline
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    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General 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
    • B29C66/73General 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
    • B29C66/739General 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
    • B29C66/7392General 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General 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
    • B29C66/73General 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
    • B29C66/739General 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
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Abstract

一种向热固性聚合物组件上粘接半晶态或晶态热塑性聚合物的方法,所述方法包括选择相容的半晶态热塑性聚合物和未固化的热固性聚合物组件,其中未固化的热固性聚合物组件的固化温度高于半晶态热塑性聚合物的熔化温度。所述方法包括使热塑性聚合物与未固化的热固性聚合物组件接触,并加热热塑性聚合物和未固化的热固性聚合物或热固性聚合物复合物组件至热固性聚合物的固化温度,其中在热固性聚合物固化之前,未固化的热固性聚合物组件和热塑性聚合物能够至少部分相互渗透。然后冷却热塑性聚合物和固化的热固性聚合物组件,从而使热塑性聚合物非常牢固地粘接到固化的热固性聚合物组件上。

Description

聚合物或聚合物复合物组件的焊接技术
发明领域
本发明涉及在聚合物或聚合物复合物组件上形成新的官能性表面。具体地,本发明涉及改变热固性聚合物或热固性聚合物复合物的表面。本发明还涉及一种在热固性聚合物或热固性聚合物复合物组件与第二组件之间形成连接的方法,其中所述热固性聚合物或热固性聚合物复合物组件具有改性官能表面。
发明背景
热塑性聚合物(热塑性塑料)是一类主要的聚合物材料。固态热塑性聚合物通常可以被加热而软化,最终会熔化,并且当其冷却时又会恢复固体状态。这些由温度所引起的变化大多是完全可逆的。热塑性塑料可以被分为两大类:“无定形热塑性塑料”和“半晶态热塑性塑料”。在固态无定形热塑性塑料中,所有的聚合物链均以随机或无序状态排列:没有聚合物链排列在晶体结构中。在固态半晶态热塑性塑料中,结构是混合的:在材料的一些部分聚合物链以有序的晶体结构排列,而在有些部分,所述链处于无定形态。“晶态热塑性塑料”具有较高比例的结晶度,但仍然具有一些无定形部分。因此在这一讨论中,将晶态热塑性塑料分类在半晶态热塑性塑料中,并且术语“半晶态热塑性塑料”亦包括“晶态热塑性塑料”。除了这种讨论目的外,“无定形聚合物”或“无定形热塑性塑料”和“半晶态聚合物”或“半晶态热塑性塑料”均指热塑性聚合物材料类型,而不是热塑性聚合物材料任何部分的局部微观结构。
无定形热塑性塑料的特征在于其玻璃化转变温度(Tg),当进一步加热至超过该温度时,会发生逐步软化。当温度明显比玻璃化转变温度高时,这些热塑性塑料的行为类似高粘度的液体。无定形热塑性塑料的使用温度低于其玻璃化转变温度。它们也是一类通常易受化学侵蚀且易吸收流体的材料。
半晶态热塑性塑料具有明显的熔化温度(Tm),超过该温度材料熔化并其行为类似于液体。进一步升高温度,其粘度迅速降低。半晶态热塑性塑料也具有特定的玻璃化转变温度,但由于其无定形部分的存在,该温度通常低于其熔化温度。半晶态热塑性塑料是否高于或低于其玻璃化转变温度还影响这些热塑性塑料的一些特性。但因为其晶体部分非常硬,半晶态热塑性塑料通常可以在高于其玻璃化转变温度的使用温度下应用。通常半晶态热塑性塑料比无定形材料吸收更少的流体。
对于无定形热塑性塑料和半晶态热塑性塑料来说,如果不超过其分解温度,由加热或冷却所引起的变化通常是完全可逆的,而所述的分解温度,通常比玻璃化转变温度或熔化温度要高得多。
热固性聚合物是第二类聚合物,其包括环氧化物(通常称为环氧化物)、双马来酰亚胺和乙烯基酯聚合物。加成聚合反应的热固性聚合物如环氧化物在固化前(至少)由树脂(单体)和硬化剂组成,这些物质一起反应产生交联聚合物。在固化前,单体和硬化剂通常以液体形式存在,虽然它们的粘度可能很高。可以设计固化在室温或更高温度下进行,对于环氧化物来说通常高达180℃。在固化过程中,单体和硬化剂反应,混合物的粘度升高直到其变为交联的固体聚合物。这一变化是不可逆的。固化之后,热固性聚合物也具有特定的玻璃化转变温度(对环氧化物来说通常稍微高于所推荐的固化温度),高于该温度时,热固性聚合物会发生明显软化,并且热固性聚合物的行为类似橡胶。(进一步加热不会熔化聚合物-而是在更高的温度下其通常开始分解。)对于随后的处理如含有热固性聚合物(例如碳纤维/环氧化物组合物)的组件的高温连接来说这一点是很关键的,因为当接近或超过热固性聚合物的玻璃化转变温度时,可能会发生组件的尺寸变形。
复合物材料是一类由至少两种紧密连接在一起的组成材料组成的材料,其中两种组成材料作为一种材料起作用,并且其特性不同于且通常优于任何一种组成材料。所述聚合物复合物由热固性或热塑性聚合物组成,并用纤维或颗粒状增强剂增强。众所周知的聚合物复合物包括玻璃纤维增强的聚酯树脂和碳纤维增强的环氧化物。这两者都用热固性聚合物作基质,因此通常被称为热固性复合物。
热塑性聚合物和热固性聚合物之间的一个主要区别在于通过升高和降低温度,热塑性塑料可以熔化和重新固化,而热固性聚合物则不能。这种特性已经被用于焊接热塑性塑料和热塑性复合物,而热固性聚合物或热固性复合物不能简单地通过这种方式连接。
带有热塑性表面的热固性聚合物组件是有吸引力的,其某些优点是使热塑性物质可能具有增强的表面性能,并且可能焊接类似镀面的组件。这通常可以通过粘结剂粘接过程完成。在粘结剂粘接过程中,粘结剂与组件接触,其必须流动并且润湿组件,并且然后原位固化。在热固性聚合物和热塑性聚合物之间进行粘结剂连接是很常见的。在大多数常见的方法中,利用未固化的热固性聚合物如环氧化物作为粘结剂,使其与固态热塑性聚合物接触,随后使之固化。这一过程可以作为固化热固性复合物组件的方法的一部分来完成。可替换地,可以利用热塑性聚合物作为粘结剂,加热使之熔化并使之与固化的热固性组件接触。随后冷却热塑性树脂。
在这两种情况下,很难在热固性聚合物和热塑性聚合物之间产生牢固的粘结剂连接。当利用热塑性物质作为粘结剂时,连接依赖于弱的二次化学键,因此所述连接本身也是弱的。当利用未固化的热固性聚合物作为粘结剂时,在热塑性表面上,通常有少许位点用于形成强度较高的一级化学键。可以利用化学试剂对热塑性物质进行表面处理或者通过物理方法如等离子处理来强化这些化学键。这可能是耗时并且是昂贵的过程,并且对于重要应用如组装航空组件时可能不能提供足够高的强度或可靠性,并且可能仍然受化学侵蚀。
但一种在热固性和热塑性聚合物之间形成高强度连接的更好的方法是形成半渗透聚合物网。这通过使聚合物链相互渗透而在不同聚合物(此时为热固性和热塑性聚合物)的聚合物链之间形成机械互锁形式。
以前,在热固性复合物的固化过程中,在热固性聚合物固化前,应用无定形热塑性塑料的低溶剂耐受性,通过促使热固性聚合物的液态未固化组分(单体和硬化剂)迁移入无定形热塑性塑料中形成互相渗透的聚合物网而连接无定形热塑性材料与热固性复合物。这种迁移入无定形热塑性塑料中通常在低于热塑性塑料的玻璃化转变温度下发生,在这种条件下,所述材料为固态。这有效使固化的热固性复合物具有热塑性表面,在升温和某些连接压力下其具有连接类似镀面材料的能力。
上述方法以及该方法所要求的无定形热塑性塑料具有几个缺点。首先,要求本方法中所应用的无定形热塑性塑料具有低的溶剂耐受性意味着所述表面以及由所述表面所形成的任何接缝很容易受到溶剂侵蚀。另外,对于这种方法,在尝试选择材料时存在固有的困难,所述材料要能够容易且有效地进行镀面和焊接过程,同时使随后的焊接连接件具有高的使用温度。为了连接两个具有无定形热塑性表面的组件,必须充分超过热塑性塑料的玻璃化转变温度,可能要超过至少50℃,从而在合理的时间内获得高质量的连接。作为结果,这通常也超过了下面的热固性聚合物的玻璃化转变温度,而这会导致组件的刚性降低和尺寸不稳定。在连接温度下,特别是为了获得好的接触和充分的流动以得到均一的高质量连接可能需要向连接处应用高压时,如果不应用足够的工具来支撑组件,则组件的尺寸变化是可能的。如果连接过程需要足够高的温度时,则热固性聚合物或热固性复合物的降解也可能发生。如果为了提高焊件的使用温度而选择高温无定形热塑性塑料作镀面/焊接材料,则镀面和焊接过程通常必须在更高的温度下进行,从而存在热固性复合物尺寸变化或降解的危险。如果为了易于镀面和焊接而选择较低温度的无定形热塑性塑料,则使用温度可能会低得无法接受。最后,与高温无定形热塑性塑料连接通常需要特别长和/或复杂的固化周期,例如包括在低于正常固化温度下的停留时间的固化周期,从而使热固性单体和硬化剂渗透至足够的深度以获得足够的粘合强度。这可能延长组件的生产时间,从而增加生产成本。
US 5,643,390描述了一种向热固塑料复合物上粘接热塑性层的方法。所述方法包括“选择热塑性材料和热固性单体,其中所述热固性单体与所述热塑性材料具有相似的溶解度参数”。“相似的溶解度参数”按Hildebrand溶解度理论进行定义,其不适于描述具有明显极性和/或氢键力的聚合物。
该美国专利涉及应用无定形热塑性塑料。所述专利指出在半晶态聚合物中渗透剂的迁移率是极小的,而这阻止形成渗透网提供粘合强度。但其中没有讨论半晶态热塑性聚合物的相容性。
与之相反,本发明是一种利用半晶态聚合物的方法,该方法有利地允许更容易的镀面以及随后的焊接操作,并且不会降低随后的焊接连接件的溶剂耐受性。
US 5,667,881描述了一种生产整合的热固性/热塑性复合物连接件的方法。所述方法要求热塑性和热固性树脂必须相互之间部分混溶,或者相互之间在10%至60%之间混溶。该专利还说明固化温度不能明显超过热塑性树脂的玻璃化转变温度。在该温度下热塑性聚合物为固态或具有极高的粘度,并且未固化的热固性聚合物迁移进入无定形热塑性聚合物中以及半渗透网的形成是非常慢的。这一点可由其中所提到的长的固化周期得到证实。
另外,在US 5,667,881中所描述的发明还涉及利用预制的热塑料性物件形成整合连接的方法,当与形成官能性的热塑性表面相比时,其限制了应用该技术可以粘接的物件的类型。
本发明有利地减轻了上述方法的至少部分缺点,并提供了一种用于在热固性聚合物或热固性聚合物复合物上形成热塑性表面的改进方法。
本发明的另一个优点是一种连接具有热塑性表面的热固性聚合物或热固性聚合物复合物组件与具有合适热塑性表面的第二组件的改进方法。
发明概述
第一方面,本发明提供一种向热固性聚合物组件上粘接半晶态或晶态热塑性聚合物的方法,所述方法包括:
选择相容的半晶态热塑性聚合物和未固化的热固性聚合物组件,其中未固化的热固性聚合物组件的固化温度高于半晶态热塑性聚合物的熔化温度,
使热塑性聚合物与未固化的热固性聚合物组件接触;
加热热塑性聚合物和未固化的热固性聚合物或热固性聚合物复合物组件至热固性聚合物的固化温度,其中在热固性聚合物固化之前,未固化的热固性聚合物组件和热塑性聚合物能够至少部分相互渗透;和
冷却热塑性聚合物和固化的热固性聚合物组件,从而使热塑性聚合物非常牢固地粘接到固化的热固性聚合物组件上。
第二方面,本发明提供一种向热固性聚合物组件上粘接半晶态或晶态热塑性聚合物的方法,所述方法包括:
选择相容的半晶态热塑性聚合物和未固化的热固性聚合物组件,其中未固化的热固性聚合物组件可以在或低于热固性组件的固化温度下迁移入半晶态热塑性聚合物中;
使热塑性聚合物与未固化的热固性聚合物组件接触;
加热热塑性聚合物和未固化的热固性聚合物或热固性聚合物复合物组件至热固性聚合物的固化温度,其中在热固性聚合物固化之前,未固化的热固性聚合物组件和热塑性聚合物能够至少部分相互渗透;和
冷却热塑性聚合物和固化的热固性聚合物组件,从而使热塑性聚合物非常牢固地粘接到固化的热固性聚合物组件上。
在本发明的第二方面中,热固性组件的固化温度可能会低于半晶态热塑性聚合物的熔化温度。
在本发明的上述任一实施方案中,热固性聚合物组件可以是热固性聚合物或者热固性聚合物复合物。当热固性聚合物组件为复合物时,在热固性聚合物固化前,当加热时,热塑性聚合物与热固性聚合物复合物的未固化热固性聚合物部分能够至少部分相互渗透,从而使热塑料性聚合物粘接到热固性聚合物复合物上。
热塑性组件与热固性组件的相容性指的是热塑性组件与热固性组件通过紧密匹配它们各自的溶解度而相互渗透的能力。
有利地,热塑性聚合物可以为热塑性聚合物组件或带有相容的热塑性聚合物表面的任何组件。
应该意识到,随着热塑性和热固性树脂间的相互渗透,热塑性聚合物表面非常牢固地粘接到热固性聚合物或热固性聚合物复合物上。这将确保热塑性表面不会很容易地从热固性聚合物或热固性聚合物复合物上脱除。
应该意识到,按照本发明第一或第二方面制备的带有热塑性表面的固化热固性聚合物或热固性聚合物复合物可以通过二次固化过程而与热固性聚合物或热固性聚合物复合物的另一部分粘接,其中所述二次固化过程按照本发明的第一或第二方面进行。
热塑性聚合物优选为聚偏二氟乙烯(PVDF),可以为纯PVDF或与含有与其它聚合物和/或常规添加剂组合的PVDF的材料。
另外,热塑性聚合物可以含有少量附加材料,例如轻质疏松织物。可替换地,热塑性聚合物可以含有少量能够导电或可局部加热的材料,例如铁磁性颗粒或其它导电材料。
热塑性聚合物可以为膜或粉末形式,或者直接涂覆于模具或工具表面上。不会粘附于热塑性塑料上的附加材料可以在制备过程中与热塑性膜相邻放置,从而改进制备成的热塑性塑料的表面质量。
在组件表面的热塑性塑料的厚度可以变化。
热固性聚合物优选为在合适升温下固化的树脂/硬化剂混合物。当为热固性聚合物复合物时,所述复合物为用一种或多种其它材料增强的合适热固性聚合物。更优选的热固性聚合物为环氧化物或双马来酰亚胺。
本发明的第三方面利用本发明第一或第二方面提供的带有半晶态或晶态热塑性表面的固化热固性聚合物或固化热固性聚合物复合物。
相应地,本发明的第三方面提供一种连接带有热塑性表面的热固性聚合物或热固性聚合物复合物组件与具有热塑性表面的第二组件的方法,其中所述带有热塑性表面的热固性聚合物或热固性聚合物复合物组件按照本发明第一或第二方面形成,所述方法包括:
放置并保持热固性聚合物组件或热固性聚合物复合物的热塑性表面与第二组件的热塑性表面紧密接触;
加热各热塑性表面至高于其熔化温度,保持一段时间,从而热塑性表面熔化并且相邻的热塑性表面焊接在一起;和
冷却熔化的热塑性塑料,从而使热固性或热固性复合物组件与第二组件之间牢固粘接。
热固性聚合物复合物组件的热塑性表面有利地按本发明的第一或第二方面形成。
热固性聚合物组件可以为热固性聚合物或热固性聚合物复合物。
第二组件优选为具有热塑性表面的热固性聚合物或热固性聚合物复合物组件,从而可以应用本发明的第三方面的方法在两个具有热塑性表面的热固性聚合物或热固性复合物组件之间形成连接。
可替换地,所述第二组件可以为热塑性聚合物或热塑性聚合物复合物,或者为具有合适热塑性表面的任何其它组件。
当紧密接触时,熔化的热塑性表面提供高的热塑性聚合物流动,从而填充相对表面中的任何起伏。通过在加热过程中提高温度和/或对两个组件应用更高的压力或者增加处理时间可以增强流动。
所述方法可以进一步包括按需在热塑性表面间添加另外的半晶态或晶态热塑性材料层,从而填充缝隙或提供高的热塑性聚合物流动。当应用附加的热塑性材料时,加热步骤还包括加热附加的热塑性材料至高于其熔化温度,保持一段时间,从而使热塑性层熔化并且熔合在一起。
重新加热焊接的热塑性层也可以按需拆除和重组组件。然后可以按上述相同方式再对它们进行焊接,如果在分开的组件上没有足够的热塑性材料,则在改性的热塑性表面之间添加额外的热塑性材料。
重新加热焊接的热塑性层也可以使组件再次经历焊接过程,或重新焊接,从而改进在所选择的区域内的焊接。
焊接优选在低于固化的热固性聚合物或聚合物复合物组件的玻璃化转变温度下进行。可替换地,在不明显过热热固性聚合物的温度下进行焊接。
热固性复合物组件可以包括可作为主要为热固性复合物组件的整合部件而包括的插件、泡沫或蜂窝芯、其它热塑性子部件或膜、或任何其它材料。
本发明还延伸至按照本发明的第一或第二方面制备的具有热塑性表面的热固性组件。如果合适,本发明的第一和第二方面的方法的优选特征有利地用于由所述方法形成的组件。
本发明进一步延伸至按照本发明的第三方面制备的产品。如果合适,本发明的第三方面的方法的优选特征有利地用于由所述方法形成的产品。
附图的简要描述
下面将参考附图仅通过实施例来描述本发明,其中:
图1描述了增强的热固性聚合物、热塑性层和其间所形成的半渗透网(SIPN)之间的关系。
图2示意性描述了按照本发明一种实施方案的两个热固性聚合物组件的连接。
图3示意性描述了按照本发明一种实施方案的两个热固性聚合物组件的连接。
图4描述了聚合物的Hansen溶解度图,其可以用来确定特定聚合物的溶剂适用性。
优选实施方案的描述
参照图1,在本发明的第一种实施方案中,在热固性组件的固化过程中,半晶态或晶态热塑性层10粘接到热固性聚合物或热固性复合物组件12上,从而形成半渗透的聚合物网14。通过选择与所选热固性单体相容的半晶态热塑性塑料10而实现这一过程。可以应用热力学和溶解度标准来确定合适的材料组合,这一点将下文中进行讨论。
聚合物的热力学和溶解度标准
相容材料的选择需要几个溶解度参数的紧密匹配。相容的无定形热塑性塑料的材料选择原则以混合的Gibb′s自由能(ΔGm)为基础,该原则表明:
ΔGm=ΔHm-TΔSm≤0               (1)
其中ΔHm为混合焓,T为温度,ΔSm为混合熵。然后可以应用Hildebrand-Scatchard等式来确定混合焓,如下:
ΔHm=VΦaΦbab)2           (2)
其中δa和δb为所考虑的两种材料如无定形聚合物和单体或硬化剂的溶解度参数(也被称为Hildebrand参数)。
但对于对粘接应用来说最有利的高性能半晶态热塑性塑料类材料来说,应用Hildebrand-Scatchard等式(上述等式2)是不够的,因为分子间力如极性力在很大程度上影响这些聚合物的溶解度行为。推荐应用考虑了分散、极性和氢键力的Hansen参数,因为这对这些聚合物来说是更合适的方法(参见AFM Barton“CRC Handbook of SolubilityParameters and Other Cohesion Parameters”,CRC Press,BocaRaton,1983)。应用这些参数为聚合物-溶剂的相容性提供了合理的指导。聚合物b的相容半径被定义为bR,如图4的溶解度图线所示。对任何溶剂a来说可以确定分散(δd)、极性(δp)和氢键力(δh)的Hansen溶解度参数并在图中画出。当在溶解度图线上用于定位溶剂a的三个Hansen参数(aδdaδpaδh)的点位于由bR定义的球内时,则聚合物在溶剂中是可溶的,即
[4(aδd-bδd)2+(aδp-bδp)2+(aδh-bδh)2]1/2bR        (3)
其中在这种情况下所述溶剂为单体或硬化剂,bR应用已知Hansen参数的常用溶剂通过标准试验确定。
本发明第一和第二方面的有利特征是改变了半晶态热性塑料10的“有效溶解度参数”。通过使热塑性塑料10和单体/硬化剂12达到足够高的温度可以实现这一点。在通常情况下,由于没有足够的自由能来克服聚合物晶态部分的熔化热,所述溶剂不能有效迁移通过聚合物的固态晶体部分。通过提高系统的温度来克服熔化热。在这些情况下,单体和硬化剂能够迁移通过聚合物,而在之前聚合物是不溶的。因此聚合物的“有效溶解度参数”通过引入热而得到改变。
因此用来迅速形成半渗透聚合物网14的一种方法是通过在高于半晶态热塑性塑料10的熔化温度下固化热固性聚合物12而改变半晶态热塑性塑料10的“有效溶解度参数”。但也存在第二种可能性,如本发明第二方面所述。通过仔细地匹配单体/硬化剂12和热塑料性塑料的溶解度特性,并且在合适的温度下,在用作溶剂的热固性单体存在下,可以克服晶态聚合物的熔化热,从而降低“熔化”温度至“有效熔化温度”,而后者取决于所涉及的单体/硬化剂。在这些条件下,单体和硬化剂能够在低于正常熔化温度下迁移通过聚合物。这一点在本文的实验讨论中得到证实。
应该注意的是这里所描述的熔化温度或更低的“有效熔化温度”将会为最低处理温度,并且对热固性聚合物来说标准的固化条件可能达到更高的处理温度。
材料选择和表面整合
通过在热固性聚合物或热固性聚合物复合物12的表面上形成一种基本半渗透的聚合物网(SIPN)14,可以成功地整合按照上述标准选择的半晶态热塑性材料10。该方法的一个方面是选择具有应用Hansen参数确定的溶解度的热固性聚合物和热塑性塑料,并且选择固化温度/时间周期,从而通过克服晶态组分的熔化热而使热固性单体和硬化剂能够充分迁移进入熔化的半晶态聚合物中,或者进入热塑性聚合物的晶体组分中。
在与单体和硬化剂“熔融物”接触而处理热塑性聚合物的晶态部分的过程中,允许未固化的热固性树脂和热塑性树脂迅速离散混合。组件固化后,通过在原始表面区域中分子链的缠绕,使热塑性膜10与组件12紧密粘接在一起,从而在热固性树脂和热塑性树脂间形成半渗透聚合物网14。
当已经满足上述热力学和溶解度相容性标准时,通常有利地是在对制造商推荐的热固性聚合物的固化周期不作任何改变的条件下进行粘接过程。
进一步的选择标准也可以有利于随后的热固性聚合物或热固性聚合物复合物16、18的焊接过程,从而使半晶态热塑性聚合物20的熔点(Tm)低于固化的热固性聚合物或热固性聚合物复合物16、18的玻璃化转变温度(Tg)。下列讨论将涉及这种情况,但应该意识到的是本发明并不局限于这一材料选择,但这种合适的选择将会得到附加的优点。
焊接技术
上述热力学讨论涉及为了在热固性聚合物或热固性聚合物复合物的表面上整合热塑性材料而选择半晶态热塑性塑料。如本发明第一方面所述,在焊接两个主要的热固性复合物组件时,选择熔化温度低于固化的热固性聚合物或聚合物复合物组件的Tg的半晶态热塑性材料具有明显的优点。
如图2所示,按照本发明的第三种实施方案,按照本发明第一或第二方面形成的具有半晶态热塑性表面20的热固性聚合物或热固性复合物组件16可以在外部加热和加压(加热压盘24)条件下与具有合适热塑性表面22的第二组件18相连接。另外,如图3示意性描述的,加热元件26或允许在焊线上集中加热的其它材料可以用于连接两个组件16、18。
第二组件也可以为具有半晶态热塑性表面的热固性聚合物或热固性复合物组件,下面的讨论将涉及这种情况,但将会理解的是本发明的第二种实施方案并不局限于此,而是广泛延伸至在具有半晶态热塑性表面的热固性聚合物或热固性复合物组件和具有合适热塑性表面的任何其它组件间形成连接,其中所述具有半晶态热塑性表面的热固性聚合物或热固性复合物组件按照本发明第一或第二方面形成。
热固性聚合物或热固性复合物组件的热塑性聚合物表面的夹杂物使两个主要由不同热固性聚合物或热固性聚合物复合物或其它材料制备的但具有类似表面材料的两个组件的连接成为可能。
焊接热塑性层的过程在加热条件下进行,并且在大多数情况下需要应用压力。热塑性层被加热至高于其熔化温度并且低于热固性聚合物或热固性复合物组件的玻璃化转变温度的温度。当热塑性塑料的熔化温度低于所要连接的热固性组件的玻璃化转变温度时,所述组件可以在不应用支撑工具的条件下在合适的环境下被连接,并且在连接过程中组件不会发生永久性变形。另外当暴露于低于热固性聚合物的玻璃化转变温度的温度下适度时间时,热固性聚合物或热固性复合物不可能降解。这减少或消除了对仅在接缝处集中加热的昂贵或复杂的加热系统的需求。
另外,由于焊接过程在高于半晶态或晶态热塑性塑料的熔化温度下进行,因此即使在非常低的焊接压力下,在焊接过程中热塑性塑料仍有相当大的流动。这种在其熔化温度之上的流动程度是本申请中半晶态热塑性聚合物的内在优点。这种流动使热塑性塑料填充在由于正常生产偏差而产生的组件表面的小起伏中或组件间的小缝隙内,并且这一点对实际的焊接过程来说是非常重要的。这减少了这种操作的工具成本,并且减少了在过程中主要为热固性复合物组件发生变形的可能性。
本发明还允许简单脱焊及分离任何焊接组件。这些组件或其焊接区域可以被加热至高于半晶态或晶态热塑性塑料的熔化温度的温度。本发明的一个优点是通过在接缝附近应用外热,可以分离热固性聚合物或热固性复合物组件,并且不需要埋入元件。在该温度范围内仅需要较小的力来分离组件。当每个组件保留其大部分热塑性表面层时,由于在镀面过程中形成了半渗透聚合物网,分离的组件可以随后按上述相同的方式再次被焊接。如果没有足够的热塑性材料保留在分离的组件上,则如果需要,可以在改性的热塑性表面之间添加半晶态或晶态热塑性材料的额外层。
另外,如果希望,在该温度范围内,所述组件可以再次进行焊接过程,或重新焊接,从而改进所选区域内的焊接。
虽然上述大部分内容均涉及为了随后连接热固性组件而使带有半晶态或晶态热塑性膜的热固性复合物的镀面过程,但产生牢固粘接于热固性聚合物或复合物组件上的热塑性官能性半晶态聚合物表面也可以提供附加的明显优点,例如改进的化学物质耐受性、降低的吸水性、改进的耐磨和耐腐蚀性、改进的表面外观、改进的摩擦特性、改进的表面电学特性、改进的耐火性或减少的由于着火而产生的烟、改进的抗UV性能、改进的表面抗裂性能、改进的生物相容性能、改进的被灭菌性能或降低了的凹痕敏感性。具体地,本发明的第一或第二方面的方法可以用于为碳纤维/环氧化物复合物提供牢固粘接的耐腐蚀表面。
还将理解的是本发明提供一种在热塑性塑料或基于不同热塑性聚合物的热塑性复合物的表面上整合半晶态聚合物的机会。在这种情况下,通过该项技术能够在与热塑性母体材料所需要的不同焊接条件下提供不同的表面特性或连接组件的能力。另外,该项技术将允许多种热塑性材料或热塑性复合物材料粘接于上面所讨论的具有半晶态聚合物表面的热固性材料或热固性复合物材料上。
实验讨论
镀面方法
制备带有半晶态聚合物表面的两个分离的复合物板。首先,将熔点约为170℃的单层PVDF半晶态热塑性膜(127μm厚)放置在含有T300碳纤维和Hexcel F593环氧树脂的一块预浸渍的光面织物上。在放置在这块织物上之前,所述膜用异丙醇清洗。将这块织物放置在一个平的工具上,并密封在真空袋内。排空真空袋内的空气,并且随后在177℃及0.63MPa的外部压力下将这块织物固化120分钟。固化后,热塑性层与复合物基材完全整合。第二块板用放置于由玻璃纤维和Hexcel F155组成的预浸渍缎质织物块上的单层127μm的PVDF半晶态热塑性膜制备。在放置在这块织物上之前,所述膜用异丙醇清洗。将这块织物放置在一个平的工具上,并且密封在真空袋内。排空真空袋内的空气,并且随后在127℃及0.32MPa的外部压力下将这块织物固化固化120分钟。固化后,热塑性表面层与复合物基材完全整合。
连接方法
用异丙醇清洗两个具有相同的热固性复合物基材和热塑性表面的复合物组件,并使所述热塑性表面相互接触。当加热至185℃并应用0.1MPa的压力20分钟后,T300/F593和GF/F155环氧化物复合物具有粘接性。在所需温度和压力下保持组件,从而使其完全封合,并在保持压力时冷却组件。冷却至室温后,将所述组件焊接在一起。
粘接强度
应用搭接剪切的粘接试验样品确定粘接强度,所述样品的宽度为25mm,接缝长度为12.5mm。在环境条件下在1.25mm/min的速度下测试样品。对于T300/F593环氧化物复合物观察到的平均粘接强度为29.1MPa。将该值与应用环氧化物粘接膜粘接的另一相同样品所观察到的平均粘接强度24.4MPa进行比较。另外,对于玻璃纤维/F155环氧化物复合物观察到27.6MPa的平均粘接强度。
压力要求
应用各种焊接压力的试验表明应用50kPa至1MPa的压力都可以形成高质量的焊接。优选压力在100kPa至350kPa之间。但是对于确保焊接来说,所应用的压力并不是必须的,而是用来使相邻的热塑性聚合物表面完全且紧密地接触,并且用来确保某些聚合物的流动。在生产实践中,应用压力可以克服尺寸偏差的微小波动。在这种热塑性连接的情况下,除了使表面相互之间接触使聚合物链迁移通过原始表面并因此封合接缝之外,不需要附加的压力。也可以应用更高的压力(1MPa或更高)迫使夹带的空气逸出接缝。应该注意的是焊接压力有可能会将一些热塑性塑料挤出刚刚连接的区域。
连接时间
聚合物具有自身封合的能力,并且需要花时间来完成这一过程,此时,分子链穿过原始连接线并与来自相邻表面的聚合物链相互缠绕,这些都与热塑性表面的温度即聚合物链的活性水平有关。
应该理解的是本说明书中所公开和定义的本发明将延伸至所提到的或者从文字和附图来看很明显的两个或多个单独特性的所有可替换组合。所有这些不同的组合构成本发明的各个可替换的方面。

Claims (28)

1.一种向热固性聚合物组件上粘接半晶态或晶态热塑性聚合物的方法,所述方法包括:
选择相容的半晶态热塑性聚合物和未固化的热固性聚合物组件,其中未固化的热固性聚合物组件的固化温度高于半晶态热塑性聚合物的熔化温度,
使热塑性聚合物与未固化的热固性聚合物组件接触;
加热热塑性聚合物和未固化的热固性聚合物或热固性聚合物复合物组件至热固性聚合物的固化温度,其中在热固性聚合物固化之前,未固化的热固性聚合物组件和热塑性聚合物能够至少部分相互渗透;和
冷却热塑性聚合物和固化的热固性聚合物组件,从而使热塑性聚合物非常牢固地粘接到固化的热固性聚合物组件上。
2.权利要求1的方法,其中热固性聚合物组件为热固性聚合物。
3.权利要求1的方法,其中热固性聚合物组件最初未固化,并且形成热固性聚合物复合物的一部分。
4.权利要求3的方法,其中在热固性聚合物固化前,当加热时,热塑性聚合物和热固性聚合物复合物的未固化热固性聚合物部分能够至少部分相互渗透,从而使热塑性聚合物粘接到热固性聚合物复合物上。
5.一种向热固性聚合物组件上粘接半晶态或晶态热塑性聚合物的方法,所述方法包括:
选择相容的半晶态热塑性聚合物和未固化的热固性聚合物组件,其中未固化的热固性聚合物组件可以在或低于热固性组件的固化温度下迁移入半晶态热塑性聚合物中;
使热塑性聚合物与未固化的热固性聚合物组件接触;
加热热塑性聚合物和未固化的热固性聚合物或热固性聚合物复合物组件至热固性聚合物的固化温度,其中在热固性聚合物固化之前,未固化的热固性聚合物组件和热塑性聚合物能够至少部分相互渗透;和
冷却热塑性聚合物和固化的热固性聚合物组件,从而使热塑性聚合物非常牢固地粘接到固化的热固性聚合物组件上。
6.权利要求5的方法,其中热固性组件的固化温度低于半晶态热塑性聚合物的熔化温度。
7.权利要求5或6的方法,其中热固性聚合物组件为热固性聚合物。
8.权利要求5或6的方法,其中热固性聚合物组件最初未固化,并且形成热固性聚合物复合物的一部分。
9.权利要求8的方法,其中在热固性聚合物固化前,当加热时,热塑性聚合物和热固性聚合物复合物的未固化热固性聚合物部分能够至少部分相互渗透,从而使热塑性聚合物粘接到热固性聚合物复合物上。
10.前述权利要求任一项的方法,其中热塑性聚合物为热塑性聚合物组件或具有相容的热塑性聚合物表面的组件。
11.前述权利要求任一项的方法,其中热塑性聚合物为纯的聚偏二氟乙烯、或含有与其它聚合物和/或添加剂组合的聚偏二氟乙烯的热塑性聚合物。
12.前述权利要求任一项的方法,其中热塑性聚合物含有少量轻质疏松织物。
13.权利要求1至11任一项的方法,其中热塑性聚合物含有能够导电或可局部加热的材料。
14.权利要求13的方法,其中所述能够导电或可局部加热的材料为铁磁性颗粒或其它导电材料。
15.前述权利要求任一项的方法,其中热塑性聚合物为膜或粉末的形式。
16.前述权利要求任一项的方法,其中热塑性聚合物被直接涂覆于模具或工具的表面。
17.前述权利要求任一项的方法,其中热固性聚合物为在升温下固化的树脂/硬化剂混合物。
18.前述权利要求任一项的方法,其中热固性聚合物为环氧化物或双马来酰亚胺。
19.前述权利要求任一项的方法制备的一种带有热塑性表面的固化热固性聚合物或热固性聚合物复合物组件。
20.一种焊接带有热塑性表面的热固性聚合物或热固性聚合物复合物组件与具有热塑性表面的第二组件的方法,其中所述带有热塑性表面的热固性聚合物或热固性聚合物复合物组件按照权利要求1-18任一项的方法形成,所述方法包括:
放置并保持热固性聚合物组件或热固性聚合物复合物的热塑性表面与第二组件的热塑性表面紧密接触;
加热各热塑性表面至高于其熔化温度,保持一段时间,从而使热塑性表面熔化并且相邻的热塑性表面焊接在一起;和
冷却熔化的热塑性塑料,从而使热固性或热固性复合物组件与第二组件之间牢固粘接。
21.权利要求20的方法,其中第二组件为具有热塑性表面的热固性聚合物或热固性聚合物复合物组件。
22.权利要求21的方法,其中第二组件按照权利要求1-18任一项的方法形成。
23.权利要求20的方法,其中第二组件为热塑性聚合物或热塑性聚合物复合物,或者为具有合适热塑性表面的任何其它组件。
24.权利要求20至23任一项的方法,其中通过在加热过程中提高温度和/或对两个组件应用更高的压力或者通过增加处理时间来增强熔化的热塑性表面的流动。
25.权利要求20至24任一项的方法,进一步包括按需在热塑性表面之间添加另外的半晶态或晶态热塑性材料层,从而填充缝隙或提供高的热塑性聚合物流动。
26.权利要求25的方法,其中加热步骤还包括加热附加的热塑性材料至高于其熔化温度,保持一段时间,从而使热塑性层熔化并且熔合在一起。
27.权利要求20至26任一项的方法,其中在低于固化的热固性聚合物或热固性聚合物复合物组件的玻璃化转变温度的温度下进行焊接。
28.一种具有热塑性表面的热固性聚合物或热固性聚合物复合物组件,所述组件按照权利要求1至18任一项的方法形成并且按照权利要求20至27任一项的方法被焊接到具有热塑性表面的第二组件上。
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