CN1443103A - 激光焊接的光导管 - Google Patents

激光焊接的光导管 Download PDF

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Publication number
CN1443103A
CN1443103A CN01809576A CN01809576A CN1443103A CN 1443103 A CN1443103 A CN 1443103A CN 01809576 A CN01809576 A CN 01809576A CN 01809576 A CN01809576 A CN 01809576A CN 1443103 A CN1443103 A CN 1443103A
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Prior art keywords
photoconductive tube
laser emission
exit surface
accordance
inlet surface
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CN01809576A
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English (en)
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大卫·A·格勒维尔
贾斯廷·R·比克福德
唐纳德·C·洛维特
保罗·A·鲁内
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Branson Ultrasonics Corp
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Branson Ultrasonics Corp
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Publication of CN1443103A publication Critical patent/CN1443103A/zh
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—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
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1664—Laser beams characterised by the way of heating the interface making use of several radiators
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/035—Aligning the laser beam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/064—Shaping the laser beam, e.g. by masks or multi-focusing by means of optical elements, e.g. lenses, mirrors or prisms
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/073—Shaping the laser spot
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—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
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—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
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1654—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—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
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1664—Laser beams characterised by the way of heating the interface making use of several radiators
    • B29C65/1667—Laser beams characterised by the way of heating the interface making use of several radiators at the same time, i.e. simultaneous laser welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—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
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1674—Laser beams characterised by the way of heating the interface making use of laser diodes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—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
    • B29C65/16—Laser beams
    • B29C65/1687—Laser beams making use of light guides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/347—General aspects dealing with the joint area or with the area to be joined using particular temperature distributions or gradients; using particular heat distributions or gradients
    • B29C66/3472—General aspects dealing with the joint area or with the area to be joined using particular temperature distributions or gradients; using particular heat distributions or gradients in the plane of the joint, e.g. along the joint line in the plane of the joint or perpendicular to the joint line in the plane of the joint
    • 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
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24—Coupling light guides
    • G02B6/42—Coupling light guides with opto-electronic elements
    • G02B6/4296—Coupling light guides with opto-electronic elements coupling with sources of high radiant energy, e.g. high power lasers, high temperature light sources
    • 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
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0822—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using IR radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—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
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    • B29C65/1603—Laser beams characterised by the type of electromagnetic radiation
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—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
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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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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    • B29C66/70—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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—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
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    • G02B6/4201—Packages, e.g. shape, construction, internal or external details
    • G02B6/4202—Packages, e.g. shape, construction, internal or external details for coupling an active element with fibres without intermediate optical elements, e.g. fibres with plane ends, fibres with shaped ends, bundles
    • G02B6/4203—Optical features

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  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Electromagnetism (AREA)
  • Toxicology (AREA)
  • Plasma & Fusion (AREA)
  • General Physics & Mathematics (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Light Guides In General And Applications Therefor (AREA)

Abstract

本发明涉及利用光导管(14)把激光束引向焊接区的方法和设备。光导管包括入口端面(22)、出口端面(24)和介于其间的柔性本体。光导管的入口端面在操作上与诸如二极管(16)之类的激光源耦接，并且适合于接收并通过光导管传送激光辐射。光导管由柔性材料形成，以便允许光导管的出口端面与复杂的二维和三维焊接区结构间隔一定的距离并与之对准。当激光辐射(20)从入口端面进入并穿过光导管的出口端面时，光导管的内部反射把激光辐射(20)包含于其中。光导管和对应的零件焊接方法允许激光焊接复杂的几何构形。

Description

激光焊接的光导管
技术领域
本发明涉及零件的激光或红外焊接，更具体地说涉及把激光能量传送到焊接区的导管。
背景技术
零件焊接领域包含各种技术，包括超声焊接、热焊接和最新的塑料零件的通过传送红外(Through Transmission Infrared)(TTIr)焊接。在TTIr焊接中，恰当波长的激光辐射穿过第一透明塑料零件，冲击吸收聚合物，因此吸收聚合物被加热到临界熔化温度。当吸收聚合物零件开始熔化时，零件被挤压在一起。随着熔化物的冷却，焊缝或熔合部分把零件连接在一起。
虽然TTIr焊接技术已得到显著进步，但是与焊缝的完整性和均匀性以及把激光能量传送到焊接区的控制有关的困难仍然是妨碍TTIr焊接的普遍商业应用的一些因素。在多数TTIr系统中，通过激光器或者工件的移动，激光光斑跟踪焊缝。另一种方法是借助激光二极管的协同调整，照射整个焊接区。同时照射方法具有许多优点，包括产生焊缝的速度和最后得到的熔合部分的均匀性。但是，整个焊接表面的同时照射要求相对于工件准确对准激光二极管。就由线性或简单几何形状结构组成的焊接区来说，二极管的对准不会明显妨碍TTIr焊接技术的应用。但是，对于具有复杂二维或三维弯曲部分的焊接区来说，二极管对准很重要。对于具有复杂弯曲部分的焊接件来说，安装二极管的岐管必须允许二极管的三维旋转和三维移动，以便进行恰当的对准。对于每种应用，岐管的结构时常不同，并且在某些情况下可能费用很高。
和二极管阵列的结构有关的另一困难在于阵列内的单个二极管一般被调整成彼此稍微重叠，以便沿着焊接区提供均匀的能量。在这种结构中，焊接过程中称为发射器的二极管或二极管元件的故障会在焊接区内产生所经受的激光能量较少的区域。会在焊缝中产生缺陷。虽然可使用反馈电路来检测发生故障的二极管，防止产生大量的不合格零件，不过在继续生产之前应更换发生故障的二极管。
发明内容
本发明集中于把激光束引向红外/激光焊接的焊接区的方法和设备。虽然本发明可能最适合于供TTIr焊接使用，不过也可用于诸如表面加热之类的其它红外/激光焊接方式中。本发明允许在不必和焊接区结构直接对应的结构中安装激光二极管。通过透明的柔性片状材料(这里称为光导管(light guide))传送由各个二极管产生的激光能量。光导管的入口表面和出口表面一般光滑，以使扩散降至最小，并且光导管最好由提供完全内部反射的柔性材料形成。光导管的轮廓可被加工成使其出口表面和焊接轮廓相符，同时允许把二极管安装在诸如平直岐管之类的相异结构中。
根据下述详细说明，本发明的其它适用范围将变得显而易见，但是，应明白指出本发明的优选实施例的详细说明和具体例子只是作为例子给出的，因为对本领域的技术人员来说，根据下述详细说明，本发明的精神和范围内的各种变化和修改是显而易见的。
附图说明
根据下面给出的详细说明和附图，可更充分地理解本发明，其中：
图1图解说明塑料零件的TTIr焊接的常规二极管结构；
图2是本发明的第一实施例的顶视图；
图3是图2中所示的焊接装置的侧视图；
图4是本发明的第二实施例的顶视图；
图5是图4中所示的焊接装置的侧视图；
图6是在不具有定向扩散的情况下，根据本发明的激光二极管阵列的顶视图；
图7是类似于图6所示的顶视图，其中本发明包括定向扩散；
图8是类似于图6所示的顶视图，其中具有一个发生故障的二极管；
图9是类似于图7所示的顶视图，其中具有一个发生故障的二极管；
图10是本发明的又一实施例的顶视图，它包括位于二极管阵列和光导管的入口表面之间的扩散透镜；
图11是本发明的顶视图，其中光导管在二维平面内变化；
图12是图11中所示的二极管和光导管的侧视图；
图13是使用光导管把激光能量从二极管阵列传送给工件的二极管阵列的视图；
图14是圆形焊接区的典型安装结构的视图。
具体实施方式
图1图解说明了激光焊接的一个常用方法，其中来自诸如二极管4之类光源的激光辐射2被用于焊接零件。理论上光辐射或激光辐射百分之百穿过正被焊接的透明塑料零件10，但是被另一塑料零件或者黑色零件12吸收。如前所述，为了使用这种方法照射整个焊接面，一般在二极管阵列中并排放置一系列的二极管，以便产生一条与焊接线的轮廓匹配的线条。随着焊接区几何形状复杂性的增大，对准并安装二极管的任务变得越来越困难。因此，常规二极管阵列的应用所固有的一些主要问题包括二极管的放置、调整、功率均匀性和固定。
图2-14中图解说明了改进的焊接技术和本发明的光导管。如图所示，光导管14被放置在激光二极管16和工件18之间，以便起二维纤维光缆的作用。激光二极管16产生一列辐射20，由于光导管14的百分之百内部反射的缘故，所述辐射20被保留在光导管14入口表面22和出口表面24之间内。光导管14最好由一片柔性材料，例如橡胶、硅橡胶或者可以模塑或变形成如图11和12中所示，并且下面描述的所需形状的任意透明热塑性材料制成。还可以用以形成类似于薄片的几何形状的方式安装的透明光纤构成光导管14。光导管14的柔软性允许在不存在用于调整或操纵的复杂机械装置的情况下，把激光辐射引向焊接区。此外，薄片的柔韧性使得能够相对简单并且费用不高地匹配焊接轮廓内较复杂的三维弯曲部分。
光导管14的出口表面24最好与工件18间隔一定距离并被定向，以确保激光在恰当的位置冲击工件18。一旦在工件18中产生了充分的热量提供分别沿透明零件10和吸收零件12的内表面充分熔化，则关闭辐射，允许熔化物浸润并粘合在一起，随后固化从而产生焊缝。一般通过向工件18加压促进焊缝的混合和固化。
如前所述，本发明克服了现有技术中的许多问题，包括二极管阵列的放置、调整和固定，以及由该组件产生的功率均匀性。本说明首先讨论光导管14本身的优选性质和操作，之后说明通过利用光导管14获得的功率均匀性和相对于工件18调整光导管14的出口表面24的例证方法和结构。光导管14最好由可模塑成其所需形状的柔性透明热塑性材料制成。光导管14提供的柔性大小可相对于任意适当的应用而变化。事实上，在某些应用中，刚性光导管材料最合适。此外，光导管14可由多层或多条纤维材料组成，以便优化光导管14的光传送性质，同时提供足够的结构支持。
光导管14的另一重要性质是该材料提供几乎百分之百的内部反射，从而整个激光束20被保持在光导管14内。所以，光导管14的光密度比空气高。
光导管14最好能够具有在出口表面24的整个表面内形成均匀光束的散射性质。入口表面22和出口表面24一般被分别抛光，以便有利于激光辐射20进出光导管14。一般来说，入口表面22和出口表面24最好是“光学光滑的”，即，在入口表面22和出口表面24的每一侧的图像质量是一致的。已确定当使用塑料薄片作为光导管14时，可利用沙纸分别磨光入口表面22和出口表面24，随后用火焰轻刷入口表面22和出口表面24，产生光学光滑边缘从而使光损失降至最小。尽管如本例所示，也可使用本领域中一般已知的各种技术为其它光导材料提供光学光滑边缘。使入口表面22和出口表面24(例如当光导管14由硅橡胶形成时)对激光辐射20的阻力降至最小的另一种适用技术是利用诸如硅填料之类的恰当粘合剂在入口表面22耦接玻璃板或者其它光滑透明材料。
在许多应用中，最好在光导管14内把激光能量扩散或者随机化到比由光导管14自身所提供的扩散程度更高的程度。在这些情况下，可分别制备光导管14的入口表面22或出口表面24，以便提供定向扩散(diffusion)。例如，通过用沙纸沿圆周方向磨擦入口表面22，可增大一个方向上光导管14提供的扩散，如附图标记26代表的区域中所示(图4)。可这样形成磨擦，使得图5中所示的侧视图中图解说明的扩散和图3中所示的相同。本领域中一般已知的各种技术可用于分别磨擦入口表面22或出口表面24，包括和平版印刷中使用的化学蚀刻类似的化学蚀刻技术。这种定向扩散允许光线散射通过薄片的厚度，从而降低或者消除光导管14两端之间的任何功率密度变化。最后的结果是在焊接面得到更均匀的功率分布。在一些情况下，必须掩蔽边缘处激光的“过多喷射”。可用于使光线随机化的另一种技术是使用具有相对于输入和输出位置的无规混合的许多光纤。
定向扩散提供的其它优点包括当使用多个二极管时，降低故障二极管或发射器的不利影响，并且更均匀。更具体地说，由于二极管16的局部效应的结果，不具有定向扩散的激光二极管16和光导管14结构(图6)产生多个峰值和谷值。另外，如图8中所示，当该结构中的二极管16发生故障时，会在焊接区内产生由此引起的“盲区”25。这些“盲区”25导致作用于工件18的不充分加热，于是导致不均匀的焊接。如图7和9中所示，由光导管14提供的定向扩散或随机化在整个光导管14内散布激光辐射20，并且在恰当的光导管14长度和内部扩散的情况下，即使由于二极管16的局部效应而产生峰值和谷值，所产生的峰值和谷值也非常少。另外，如图9中所示，当该结构中的二极管16发生故障时，在焊接区中也不会产生任何“盲区”。
通过在入口表面22的上游(图10)或者在出口表面24的下游放置一个独立的透镜31，可进一步提高定向扩散或随机化，或者使之更适合于特定的应用。在本领域中这种扩散透镜为人们所熟知。
如前所述，光导管14提供的主要优点在于离开光导管14的出口表面24的激光能量的位置和模式适合于特定的应用，更具体地说，适合于焊接区的特定几何形状。柔性薄片可具有易于匹配复杂的焊接区几何形状的二维或三维弯曲部分。图11和12中图解说明了例证的二维弯曲部分。更具体地说，图12表示由光导管14提供的百分之百内部反射，以便改变离开光导管14的出口表面24的激光束的一般定向和均匀性。这允许在不存在调整和操纵激光二极管16的复杂机械装置的情况下，把激光辐射20引向焊接区。二极管16几乎可安装在包括平直岐管在内的任意结构上。应注意光导管14能够提供的弯曲量是有限制的，并且这种限制取决于具体的应用和该应用与光导管14之间的相对折射率。例如，对于由硅橡胶、塑料或玻璃制成的光导管14(其中通过光导管14的激光辐射20的90％损失是可接受的)来说，可使用至少1/2英寸的弯曲半径。
图13和14中图解说明了例证的安装组合件。具体地说，多个激光二极管30被安装在平直岐管32上，并被定向成朝着岐管32中的中心开孔34投射激光能量。光导管36被布置成接收由各个二极管30产生的激光能量，并使激光能量经过垂直的弯曲部分进入开孔34。如图14中所示，确定出口表面的光导管36的端部37可与诸如圆柱体38之类的安装结构耦接，以便把各个光导管36固定到与焊接区匹配的结构中。在图解说明的实施例中，通过利用粘合剂，使各个光导管36的出射端37与安装圆柱体38耦接，从而与圆形焊接区匹配。可使用其它各种安装装置和组件来布置任意数目光导管36的出口表面37，以便与焊接区的复杂几何形状匹配。图14还图解说明可借助硅橡胶或者硅填料，使光导管36的入口表面39与由透明材料制成的辅助薄片40，最好是取自诸如显微镜载片的一片玻璃耦接，以使入口表面39的散射特征更适合于上述具体应用。
上述说明公开并描述了本发明的一个例证实施例。根据上述说明及附图和权利要求，本领域的技术人员会认识到在不脱离由下述权利要求所限定的本发明的精神和范围的情况下，可对其做出各种改变、修改和变化。

Claims (24)

1、一种产生把工件的透明零件耦接到工件的吸收零件的焊缝的组件，包括：
产生激光辐射的激光源；和
具有入口表面和出口表面的光导管，所述激光辐射在所述入口表面进入所述光导管，通过所述光导管并在所述出口表面离开所述光导管，所述出口表面与工件相隔一定距离，所述光导管是柔性的，从而允许所述光导管对准焊缝。
2、按照权利要求1所述的组件，还包括一个安装结构，所述激光源与所述安装结构耦接，所述激光辐射沿着不对准焊接区的方向从所述激光源发出，所述光导管具有弯曲部分并且是柔性的使得所述光导管的所述出口表面与所述焊接区对准。
3、按照权利要求1所述的组件，其中所述光导管由当所述激光辐射在所述光导管的所述入口表面和所述出口表面之间通过时，扩散所述激光辐射的材料形成。
4、按照权利要求3所述的组件，其中所述光导管由硅橡胶形成。
5、按照权利要求3所述的组件，还包括与所述光导管的所述入口表面耦接的光学透明板。
6、按照权利要求1所述的组件，其中所述光导管由当所述激光辐射在所述光导管的所述入口表面和所述出口表面之间通过时，混合所述激光辐射的材料形成。
7、一种把激光辐射传送到工件的光导管，包括：
具有入口表面、出口表面和在入口表面和出口表面之间延伸的本体的柔性薄片，所述柔性薄片内部反射激光辐射，从而当激光辐射通过所述入口表面、所述本体和所述出口表面时，把激光辐射保持在所述薄片内。
8、按照权利要求7所述的光导管，其中所述光导管的所述入口表面和所述出口表面是光滑的。
9、按照权利要求7所述的光导管，其中所述柔性薄片由透明热塑性材料形成。
10、按照权利要求7所述的光导管，其中所述柔性薄片由硅橡胶形成。
11、按照权利要求7所述的光导管，其中所述柔性薄片由玻璃纤维形成。
12、按照权利要求7所述的光导管，包括与所述柔性薄片的所述入口表面粘合的光学透明板。
13、一种零件焊接方法，包括：
产生激光辐射；
使所述激光辐射通过具有入口表面和出口表面的柔性薄片；
允许所述激光辐射在所述出口表面离开所述柔性薄片；和
利用所述激光辐射冲击要焊接的零件，产生焊缝。
14、按照权利要求13所述的方法，其中所述柔性薄片的所述入口表面和所述出口表面是光滑的。
15、按照权利要求13所述的方法，其中所述柔性薄片由透明热塑性材料形成。
16、按照权利要求13所述的方法，其中所述柔性薄片由硅橡胶形成。
17、一种产生连接第一和第二零件的焊接连接的方法，包括：
使产生激光辐射的激光源和安装结构耦接；
在操作上使光导管的入口端部和所述激光源耦接，使得所述激光辐射进入所述光导管；
使所述光导管的出口端部位于与零件相隔一定距离，并且与要形成的焊接连接对准；
通过所述光导管传送激光辐射；和
允许所述激光辐射离开所述光导管，并冲击零件形成焊接连接。
18、按照权利要求17所述的方法，其中所述耦接步骤包括使多个激光源和所述安装结构耦接。
19、按照权利要求18所述的方法，其中所述光导管是柔性的，允许所述光导管对准零件。
20、按照权利要求19所述的方法，其中所述光导管由透明热塑性材料形成。
21、按照权利要求19所述的方法，其中所述光导管由硅橡胶形成。
22、按照权利要求19所述的方法，其中所述光导管由玻璃纤维形成。
23、按照权利要求17所述的方法，其中所述传送步骤包括当所述激光辐射传送经过所述光导管时，扩散所述激光辐射。
24、按照权利要求17所述的方法，其中所述传送步骤包括当所述激光辐射传送经过所述光导管时，混合所述激光辐射。
CN01809576A 2000-04-11 2001-04-10 激光焊接的光导管 Pending CN1443103A (zh)

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CN100572033C (zh) * 2007-05-25 2009-12-23 江苏大学 一种热塑性塑料的微焊接方法
CN108723591A (zh) * 2017-04-14 2018-11-02 汽车照明意大利独资股份有限公司 车灯的同步激光焊接设备和车灯的同步激光焊接方法
TWI714880B (zh) * 2017-10-04 2021-01-01 德商Ｌｐｋｆ雷射暨電子股份公司 光學構件、波導雷射以及製造光學構件之方法
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CN111757804B (zh) * 2018-01-22 2022-09-23 必能信超声公司 用于窄型同步激光塑料焊接的波导

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CH694939A5 (fr) 2005-09-30
WO2001076807A1 (en) 2001-10-18
US20020008089A1 (en) 2002-01-24
DE10196087B3 (de) 2019-01-10
AU2001255284A1 (en) 2001-10-23

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