CN1446682A - 顶衬/气道组件及其焊接工艺 - Google Patents

顶衬/气道组件及其焊接工艺 Download PDF

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Publication number
CN1446682A
CN1446682A CN03106012A CN03106012A CN1446682A CN 1446682 A CN1446682 A CN 1446682A CN 03106012 A CN03106012 A CN 03106012A CN 03106012 A CN03106012 A CN 03106012A CN 1446682 A CN1446682 A CN 1446682A
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CN
China
Prior art keywords
roof liner
air flue
crash roll
weld flange
welded
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN03106012A
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English (en)
Inventor
约尔格·布拉姆
罗伯特·吉福德
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Branson Ultrasonics Corp
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Branson Ultrasonics Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US10/210,161 external-priority patent/US6797089B2/en
Application filed by Branson Ultrasonics Corp filed Critical Branson Ultrasonics Corp
Publication of CN1446682A publication Critical patent/CN1446682A/zh
Pending legal-status Critical Current

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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
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C65/06—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin 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
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7841—Holding or clamping means for handling purposes
    • 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
    • B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
    • B29C66/026—Chemical pre-treatments
    • 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
    • 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
    • B29C66/114—Single butt 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
    • B29C66/05—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
    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt 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
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/13—Single 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
    • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • 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
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot 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
    • 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
    • B29C66/303—Particular design of joint configurations the joint involving an anchoring effect
    • 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
    • B29C66/50—General 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
    • B29C66/51—Joining 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
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/532—Joining single elements to the wall of tubular articles, hollow articles or bars
    • 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
    • B29C66/50—General 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
    • B29C66/51—Joining 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
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B29C66/543—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles joining more than two hollow-preforms to form said 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
    • B29C66/50—General 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
    • B29C66/61—Joining from or joining on the inside
    • 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
    • B29C66/70—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
    • B29C66/72—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 structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
    • B29C66/72141—Fibres of continuous length
    • 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
    • B29C66/70—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
    • B29C66/731—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 intensive physical properties of the material of the parts to be joined
    • B29C66/7311—Thermal properties
    • B29C66/73115—Melting point
    • B29C66/73116—Melting point of different melting point, i.e. the melting point of one of the parts to be joined being different from the melting point of the other part
    • 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
    • B29C66/70—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
    • B29C66/737—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 state of the material of the parts to be joined
    • B29C66/7377—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 state of the material of the parts to be joined amorphous, semi-crystalline or crystalline
    • B29C66/73771—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 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 amorphous
    • 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
    • B29C66/70—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
    • B29C66/737—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 state of the material of the parts to be joined
    • B29C66/7377—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 state of the material of the parts to be joined amorphous, semi-crystalline or crystalline
    • B29C66/73771—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 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 amorphous
    • B29C66/73772—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 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 amorphous the to-be-joined areas of both parts to be joined being amorphous
    • 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
    • B29C66/70—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
    • B29C66/737—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 state of the material of the parts to be joined
    • B29C66/7377—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 state of the material of the parts to be joined amorphous, semi-crystalline or crystalline
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    • B29C66/737—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 state of the material of the parts to be joined
    • B29C66/7377—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 state of the material of the parts to be joined amorphous, semi-crystalline or crystalline
    • B29C66/73773—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 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
    • B29C66/73774—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 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 the to-be-joined areas of both parts to be joined being semi-crystalline
    • 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
    • B29C66/70—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
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
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Abstract

本发明公开了一种用在车辆上的顶衬/气道组件及其焊接工艺，其是通过将顶衬和气道用振动焊连接起来、或者是通过将顶衬与组件的气道用超声焊连接起来而制成的。对于由不适于超声焊方法的材料制成的部件，可通过先在其中一个部件上粘接一种可与另一部件相适配的材料，来将它们用超声焊接方法连接起来。

Description

顶衬/气道组件及其焊接工艺
与相关申请的交叉引用
本申请与在2002年8月1日提交的、名称为“能量管理系统及其焊接工艺”的第10/210161号美国专利申请为系列申请，该申请还要求享有2002年2月20日提交的第60/358123号美国专利申请的优先权。
技术领域
本发明涉及一种用在车辆上的通风管道系统、以及用于制造这种系统的工艺。
背景技术
在当今的车辆上—例如在汽车上，用气道来将空气分配到载客室中。在某些车辆中，气道从车辆的HVAC(加热、通风、空气调节)系统通入到仪表板中，并与仪表板上的空气出口相连接。在其它一些车辆中，气道除了要通向仪表板上的出气口之外，还要在车辆的地板下方延伸，并开口在车辆的后部。在另外一些车辆中，气道延伸在车辆的顶衬和车顶之间，并开向载客室中理想位置处的排气口。
在那些气道延伸于顶衬与车顶之间的车辆中，优选地是将气道与顶衬紧固到一起。通常是通过在适当的部位处将气道和顶衬结合到一起来进行紧固的。
参见图1，一种顶衬10是一聚氨酯层或聚丙烯泡沫层12制成的，其具有一聚酯或聚丙烯背衬板14和一由纤维制成的前板16，前板16例如是用毛毡制成的，从而使顶衬在被安装到车辆中时，其可被看到的那一面(本文称为“可视面”)具有良好的外观。在用于汽车上的应用环境中，部件的可视面被称为“A级”面。聚酯/聚丙烯背衬板14和前板16通常是用粘接剂粘贴到聚氨酯/聚丙烯泡沫层12上。
将气道与顶衬粘到一起要面临很多困难。胶水必须既能与气道的材料相粘连，也能与顶衬的材料相粘连，并具有足够强且耐久的粘合力，以使得气道和顶衬能在车辆的预期寿命内都能保持在一起。但此类胶水的价格是会很昂贵的，因而希望能将胶水的用量减到最少。因此，一般只是在气道和顶衬的部分区域上涂抹胶水。胶水的涂抹操作也是很麻烦的，并增加了制造过程的工时，这反过来又会增加成本。
顶衬中还包括能量管理系统。在本文中，“能量管理系统”是指这样一种结构：其具有一基底，该基底粘接到一吸能垫或防震垫上，其中的吸能垫或防震垫例如为蜂窝结构。如图中所示出的那样，防震垫在合适的部位处被粘接到顶衬上，其中的防震垫例如为聚丙烯蜂窝构件、聚丙烯凸肋构件或其它的防震垫构件。图2是一个分解视图，表示了这样一种顶衬/防震垫能量管理系统：在该系统中，防震垫18被用粘接剂粘接到顶衬10上。在所形成的顶衬/防震垫能量管理系统中，顶衬为基底，防震垫为聚丙烯蜂窝构件、聚丙烯凸肋构件或其它的防震垫构件。
发明内容
根据本发明的一个方面，利用振动焊方法将顶衬和气道焊接到一起来制成用在车辆中的顶衬/气道组件。根据本发明的另一方面，用于车辆的顶衬/气道组件是利用超声焊接方法将顶衬和气道焊接到一起来制成的。
在本发明的一个方面，顶衬可以是一能量管理系统中的部件。
在本发明的一个方面，顶衬和气道是由不适于用振动焊进行连接的材料制成的。在进行振动焊之前，先将一层可与顶衬和气道中之一相配的适配材料粘接到顶衬和气道中的另一个上。
在本发明的一个方面，可通过这样的方法来将由不适于超声焊接的材料制成的部件焊接起来：在将两部件超声焊接到一起之前，先在其中一个部件上粘接一种可与另一部件相配的适配材料。
在本发明的一个方面，顶衬和气道是由不适于用超声焊进行连接的材料制成的。在进行超声焊之前，先将一层可与顶衬和气道中之一相配的适配材料粘接到顶衬和气道中的另一个上。
附图说明
从下文的描述和附图可对本发明有更为全面的理解，在附图中：
图1是现有技术中顶衬的分解视图；
图2是一个分解视图，表示了现有技术中的顶衬能量管理系统；
图3中的侧视图表示了放置在振动焊设备中的能量管理系统；
图4中的分解视图表示了已被振动焊接到一起的能量管理系统；
图5中的分解视图也表示了已被振动焊接到一起的能量管理系统；
图6是一个侧视图，表示了聚丙烯凸肋构件；
图7中的侧视图表示了焊接制成的夹层式聚丙烯蜂窝构件；
图8中的图样表示了用振动焊对聚合物进行焊接所形成的接口；
图9中的图样表示了由振动焊所形成的机械接点；
图10是一个侧视图，表示了根据本发明一个方面制出的气道和顶衬，图中该气道和顶衬被安装到一机动车上；
图11中的侧视图表示了放置在振动焊设备上的气道和顶衬；
图12是一个侧视图，图中的气道和顶衬被放置在一超声焊设备上；以及
图13中的图表列出了用超声焊进行连接时各种材料之间的适配性。
具体实施方式
从本质上而言，下文对优选实施例的描述仅是示例性的，在任何意义上都不应当看作是对本发明、及其应用或使用的限定。
参见图3，将对一顶衬/防震垫能量管理系统8的振动焊接过程进行描述。顶衬/防震垫能量管理系统8包括粘接到防震垫18上的顶衬(见图1)。防震垫18在图中被表示为聚丙烯蜂窝构件。但应当理解：防震垫18可以是其它的防震垫构件，例如聚丙烯凸肋构件56(见图6)。如所公知的那样，聚丙烯凸肋构件56是一种用聚丙烯材料模制成的构件，其上设置有用于吸收冲击的凸肋58。
在图3中，一摩擦焊或振动焊设备20具有一振动头22，该振动头上安装了一上压具24。振动焊设备20还具有一预先定中的夹具26，其由安装在工作台30上的动作缸28支撑着。振动焊设备20还包括压力区32，它们带有防震垫接纳夹具34。所示的压力区32可以是由密执安州的Rochester Hills地方的Branson Ultrasonics公司出品的VS-8101/1、VS-8101/2或VS-8101/7型压力区。在上压具24上安装粗糙化处理后的嵌入件36，其例如为滚花的铝制嵌入件。
图中所示的振动焊设备20可以是在名称为“摩擦焊设备”的第3920504号美国专利中所公开的振动焊设备，该专利文献的全部内容接合到本文中作为参考。
将顶衬10放置到预先定中的夹具26上，并使顶衬的可视面(纤维层16)面朝上。防震垫18被放置到防震垫夹具34上，然后启动振动焊设备20的焊接作业循环。工作台30抬高动作缸28和压力区32，将顶衬10顶入到上压具24中，且压力区32将防震垫18紧压到顶衬10的聚酯背衬板14上。当顶衬10被升高到上压具中时，预先定中的夹具26下降。然后启动振动头22，来将防震垫18紧贴着顶衬10的聚酯背衬板14进行振动，从而将防震垫18振动焊接到顶衬10上。粗糙处理的嵌入件36被设置在上压具24中，从而当顶衬10被抬升到上压具24中、且防震垫18被压力区32压紧到顶衬10上时，嵌入件36能与防震垫18相对置。在完成了振动焊作业循环后，在一段适当的保持时间内，振动焊设备20以一定压力将防震垫18顶压在顶衬10上。在经过了保持时间之后，工作台30降低，并将制造完成的顶衬/防震垫能量管理系统8从振动焊设备20中取出。
应当理解：也可将振动焊设备20设计成这样：防震垫18向上抬升到上压具24中，顶衬10向上紧顶着防震垫18。
将一个部件顶着另一个部件进行振动—在这种情况下，是将表示为聚丙烯蜂窝构件的防震垫18顶着顶衬10的聚酯背衬板14进行振动，该振动将会产生足够多的摩擦热，从而使防震垫18的聚丙烯热塑性材料与顶衬10的聚酯背衬板14熔接到一起，从而形成聚合物接点与机械接点(互锁)中的一种接点或两种接点，这取决于防震垫18和聚酯背衬板14各自的具体成分。对于聚丙烯背衬板，结合部基本上属于聚合物连接，而对于聚酯背衬板，则结合部基本上属于机械接合，在这种结合部中，聚丙烯蜂窝防震垫18的热塑性材料熔入到聚酯背衬层14的纤维周围(互锁)。应当理解：防震垫18可以是除聚丙烯蜂窝构件之外的其它构件，例如泡沫或聚丙烯凸肋构件。
可用现有的摩擦焊设备或振动焊设备来执行上述的过程，其中的设备例如是公开在前面提到的第3920504号美国专利中。随所要焊接到一起的两个部件的材质不同，焊接的参数条件也要相应地变动，以便于使两部件之间能实现合适的振动焊或摩擦焊效果。重要的焊接参数包括压力、振幅、频率、焊接时间和保持时间。
被图示为聚丙烯蜂窝构件的防震垫18可以是如下的任何一种聚丙烯蜂窝件：由英国曼彻斯特的Trauma Lite有限公司出品的、商品名为TRAUMA-LITE蜂窝板；由美国宾夕法尼亚州Canonsburg地方的ATS公司出品的PP8-80TUBUS聚丙烯蜂窝板；以及由ATS公司出品的WAVECORE聚丙烯蜂窝板。当采用Branson Ultrasonic出品的BransonUltrasonics Mini-Vibration Welder时，如将聚酯背衬的顶衬材料焊接到上述的聚丙烯蜂窝构件上时，可采用如下的示例性焊接参数：
最大夹紧载荷：            331N-340N
焊接振幅                  1.70-180毫米(波峰到波峰)
焊接时间                  1-8秒
焊接频率                  240Hz
表1列出了用Branson Ultrasonics公司的Mini-VibrationWelder将上述顶衬材料制成的工件焊接到所述蜂窝构件上、并实现接合时所采用的焊接参数。可通过常规的反复试验来确定出能实现令人满意且又最佳接合的焊接参数(蜂窝材料，尺寸为70mm×700mm，厚度为10毫米或20毫米，顶衬材料的内部带有或不带有泡沫层，并具有聚酯背衬)。
                                              表1
  序号  频率[Hz]  振幅[mm] 焊接力[N]  熔接时间[s]   保持力[N]  保持时间[s]     备注
    1     240     1.80     340     5     340     5   10毫米/不带有泡沫背衬
    2     240     1.80     340     8     340     5   10毫米/不带有泡沫背衬
    3     240     1.80     340     8     340     5   10毫米/不带有泡沫背衬
    4     240     1.80     340     8     340     5   20毫米/带有泡沫背衬
    5     240     1.80     340     8     340     8   20毫米/带有泡沫背衬
    6     240     1.80     340     5     340     5   10毫米/带有泡沫背衬
表2列出了用Branson Ultrasonics公司的Mini-VibrationWelder对夹层构件进行焊接时所采用的焊接参数，其中的夹层构件是通过将上述类型的聚丙烯蜂窝构件设置在两聚丙烯基板之间来形成的。在此方面，蜂窝构件52(见图7)的一侧被振动焊接到其中一个聚丙烯板54上，然后再将聚丙烯板54振动焊接到蜂窝构件的另一侧(即形成夹层结构)。蜂窝构件的厚度为10毫米或20毫米，聚丙烯板中的MFR(添加的矿物纤维)为20％，或加入了30％的滑石。(蜂窝材料，尺寸为70mm×700mm，厚度为10毫米或20毫米)。
                                               表2
    序号     频率[Hz]     振幅[mm]   焊接力[N]  熔接时间[s]  保持力[N]  保持时间[s]          备注
    1     240     1.80     340     8   340     8 填充有10毫米/20％MFR，夹层式
    2     240     1.80     340     8   340     8 填充有20毫米/20％MFR，夹层式
    3     240     1.80     340     5   340     5 填充有10毫米20％MFR
    4     240     1.80     340     5   340     5 填充有10毫米20％MFR
    5     240     1.80     340     8   340     5 填充有20毫米20％MFR
    6     240     1.80     340     8   340     8 填充有20毫米20％MFR
    7     240     1.80     340     8   340     8 填充有20毫米30％TF
    8     240     1.80     340     8   340     5 填充有20毫米30％TF
    9     240     1.80     340     5   340     5 填充有10毫米30％TF
    10     240     1.80     340     5   340     5 填充有10毫米30％TF
对于由不相适配材料制成的部件，例如可用粘接剂在其中一个部件或两个部件上粘附一层“相适配”的材料来执行振动焊或摩擦焊。在本文中，“相适配”材料是指可用振动焊方法焊接到另一部件或另一层相适配材料(如同可能出现的情况那样)上的材料。例如，聚氨脂泡沫是一种可被用来制造能量管理构件中防震垫的材料。但是，聚氨脂泡沫是热固性的材料，因而不能有效地执行振动焊或摩擦焊。为了能将聚氨脂等热固性材料用振动焊或摩擦焊方法焊接到聚丙烯等热塑性材料，要在要被焊接到热塑性材质部件上的、并用热固性材料制成的部件的表面上粘接一层相适配的热塑性材料—例如为聚丙烯薄板。然后，通过对这两个部件执行振动焊，从而使粘附到热固性材质部件上的热塑性材料与另一部件发生振动焊熔，从而将用热固性材料制成的部件用振动焊或摩擦焊方法焊接到由热塑性材料制成的部件上。类似地，首先通过在将要焊接到一起的、且都是用热固性材料制成的两部件上分别粘附可适配的热塑性材料层，就能将这样的两个部件也用振动焊或摩擦焊方法连接起来。例如，可将在要进行焊接的两部件的表面上分别粘附聚丙烯毛绒薄层—例如是用粘接剂。类似地，通过在其中一个要被焊接起来的部件或两个部件的表面上都粘接一层(或如可能出现的情况那样：为几层)相适配的热塑性材料，而可将用“不适配”的热塑性材料制成的部件用振动焊的方法连接起来。不适配的热塑性材料是指这样的两种热塑性材料：它们的熔点和流动指数存在显著的差别，从而不便于将这两种材料用振动焊或摩擦焊方法连接起来。相适配的热塑性材料是指这样的两种热塑性材料：它们的熔点和流动指数非常相似，从而这两种材料可被摩擦焊接或振动焊接起来。
下面转向图4，图中是一能量管理构件38的分解视图，其具有接合到一顶衬10上的一聚氨酯防震垫40。示例性地，基底42为上述类型的顶衬材料，并用纤维进行增强。图4中与图3中各个元件相对应的元件将用相同的数字标号指代。作为例证，防震垫40是由聚氨酯泡沫层44制成的，其用公知的方法在聚氨酯泡沫层44上粘接一由聚酯绒毛或聚丙烯制成的背衬层46，其中的粘接方法例如是用粘接剂或胶带。防震垫40还可选地带有一面饰层48，其可以是毛毡、聚酯绒毛或类似的材料。
以上述的方式将顶衬10放置到振动焊设备20(见图3)中，并将一层或多层防震垫40放置到防震垫夹具34(见图3)上，并使聚酯背衬层44面朝向顶衬10。然后以上述的方式将顶衬10和防震垫40振动焊接到一起。
表3列出了用Branson Ultrasonics公司的Mini-VibrationWelder对工件执行焊接来制造构件时所采用的焊接参数，其中的工件为上述典型的带有聚酯背衬的顶衬材料、以及具有聚丙烯绒毛背衬层的聚氨酯泡沫层。在表3的焊接操作中，防震垫上聚丙烯毛绒背衬层的热塑性材料会渗透顶衬10的聚酯背衬层14而形成机械接合。在两种情况下，都形成了结合部。通过反复试验的方法，可确定出最优的焊接参数。(带有聚丙烯毛绒背衬层的聚氨酯部件，厚度约为10毫米，尺寸为60毫米×15毫米)
                                          表3
  序号  频率[Hz]  振幅[mm]  焊接力[N]  熔接时间[s]   保持力[N] 保持时间[s]
    1     240     1.70     340     6     340     3
    2     240     1.70     340     6     340     3
    3     240     1.70     340     8     340     3
    4     240     1.70     340     8     340     3
    5     240     1.70     340     8     340     3
在某些情况下，用类似材料制成的两个部件具有热塑性，但该热塑性不足以允许实现有效的振动焊或摩擦焊。例如，尽管上述顶衬材料的聚酯背衬层是热塑性的，但很难将两个顶衬材料的工件用振动焊或摩擦焊连接起来。在这样的情况下，要在两聚酯背衬层之间设置一层中间热塑性材料，其可用振动焊或摩擦焊方法焊接到两个部件上。中间热塑性材料可被接合到其中一个部件上，其中的接合方法例如可以是用粘接剂进行粘接或用振动焊或摩擦焊进行焊接。然后，将另一个部件振动焊或摩擦焊到第一个部件上，具体来讲，是被振动焊或摩擦焊到第一个部件的热塑性材料层上。
采用上述过程的一个示例是用振动焊或摩擦焊将两个用上述典型顶衬材料制成的工件焊接起来。如上文所讨论的那样，由这种典型顶衬材料制成的顶衬50包括一聚氨酯泡沫层12，其具有一聚酯背衬板14和一用纤维制成的前板16，其中的纤维例如为毛毡。尽管聚酯是热塑性的，但两层聚酯材料通常是不能被有效地摩擦焊接起来的。图5是一个分解视图，图中通过在两个用所述顶衬材料制成的工件50的聚酯背衬层14之间设置一聚丙烯薄膜层51，而将它们用振动焊或摩擦焊方法焊接起来，聚丙烯薄膜51例如通过粘接剂、胶带等接合到其中一个工件50的聚酯背衬层14上，或者是通过振动焊或摩擦焊进行连接。然后将所形成的、其聚酯背衬层14上接合有聚丙烯薄膜51的顶衬工件50用振动焊或摩擦焊方法焊接到另一个工件50上，此时，聚丙烯薄膜51被振动或摩擦焊到另一工件50的聚酯背衬层14上。
表4列出了对于一些焊接操作所采用的示例性焊接参数，其中，通过用Branson Ultrasonics公司的Mini-Vibration Welder执行振动焊或摩擦焊来将两个所述的工件50连接起来(部件的尺寸约为50mm×50mm)。
                                        表4
  序号  频率[Hz]  振幅[mm] 焊接力[N] 熔接时间[s] 保持力[N] 保持时间[s]
    1     240     1.70     340     8     340     3
    2     240     1.70     340     8     340     3
    3     240     1.70     340     4     340     3
    4     240     1.70     340     5     340     3
    5     240     1.70     340     1     340     3
图8表示了在两个用聚合物制成的部件之间的分子聚合物接合，这些聚合物相互粘接到一起。如所公知的那样，在分子聚合物接合中，两部件的聚合物材料相互混合而成为一种聚合物。因而，如所公知的那样，为了将两种聚合物熔融到一起而形成一聚合物接合，如果这两种聚合物不是相同的，则它们的熔点和熔融流动指数必须是相似的。
图9表示了通过将两个部件的聚合物熔融到一起而形成的机械接合或互锁接合。在机械接合中，一个部件(例如为热塑性部件)的聚合物发生熔化，并包围另一部件(例如为纤维材料)的聚合物而发生互锁。但是，在单纯的机械接合中，两个部件的聚合物并不会如图8中分子聚合物接合的情况那样发生相互混杂。
表5列出了一些焊接参数，这些参数对应于用BransonUltrasonics公司出品的VW4型号Mini-Vibration Welder将一种蜂窝材料(由Trauma Lite生产、型号为“WAVE CORE”、且两侧面带有毛绒背衬)焊接到一种带有聚丙烯背衬层(由Lear公司生产、型号为“AZDEL”)的顶衬材料时的情况。部件被焊接到一起，且在它们之间设置了一条带，用于执行拉伸试验。(型号为“WAVE CORE”的蜂窝材料的厚度为15毫米，并带有毛绒背衬，部件的尺寸为70×120mm。型号为“AZDEL”的顶衬材料带有聚丙烯背衬，部件尺寸为200×150mm。)
                                                     表5
   序号     频率[Hz]     振幅[mm]    焊接力[N]  熔接时间[s]   保持力[N]  保持时间[s]     熔化[mm]        备注
    1     240     1.75     1134     3     1134     5     0.092-0.11   移动：蜂窝板固定：顶衬
    2     240     1.75     1588     5     1588     5     0.070-0.08   移动：顶衬固定：蜂窝板
    3     240     1.75     907     5     907     5     0.020   移动：顶衬固定：蜂窝板
    4     240     1.75     907     5     907     5     0.030-0.05   移动：蜂窝板固定：顶衬
    5     240     1.75     907     4     907     4     0.011-0.013   移动：顶衬固定：蜂窝板
    6     240     1.75     907     4     907     4     0.015-0.016   移动：蜂窝板固定：顶衬
    7     240     1.75     680     4     680     4     0.002-0.003   移动：顶衬固定：蜂窝板
    8     240     1.75     680     4     680     4     0.006-0.008   移动：蜂窝板固定：顶衬
    9     240     1.75     1360     3     1360     3     0.011   移动：顶衬固定：蜂窝板
    10     240     1.75     1360     3     1360     3     0.013-0.014   移动：蜂窝板固定：顶衬
表6列出了一些焊接参数，这些参数对应于用BransonUltrasonics公司出品的VW4型号Mini-Vibration Welder将一种聚丙烯安全塑料(由Oakwood集团生产)焊接到一种带有聚丙烯背衬(由Lear公司生产、型号为“AZDEL”)的顶衬材料时的情况，其中的顶衬材料带有聚酯背衬(由Lear公司生产)。(安全塑料的部件尺寸为100×140mm。顶衬材料带有聚丙烯/聚酯背衬，部件尺寸为120×160mm。)
序号  频率[Hz]  振幅[mm]  焊接力[N]  熔接时间[s]  保持力[N]  保持时间[s]           备注
1  240  1.75  1134  3  1134  5 移动：安全塑料固定：带有PP背衬的顶衬
2  240  1.75  1134  3  1134  5 移动：安全塑料固定：带有PP背衬的顶衬
3  240  1.75  1134  3  1134  5 移动：安全塑料固定：带有PE背衬的顶衬
4  240  1.75  1134  3  1134  5 移动：安全塑料固定：带有PE背衬的顶衬
参见图10，图中表示了一个根据本发明的一个方面制出的气道/顶衬组件10，该组件被安装到机动车102上。气道/顶衬组件100包括接合到顶衬106上的气道104。图中所示的顶衬106是上文描述的顶衬类型。应当指出的是：顶衬106是能量管理系统的一个部件，该能量管理系统例如是上述的能量管理系统8。示例地，气道/顶衬组件100可包括一第二气道104，其位于车辆102的另一侧。
气道104是通过任何公知的方式—例如通过吹塑工艺由塑料制成的，其中的塑料通常为聚乙烯或聚丙烯。气道104的一端具有一进气口108，该进气口通向车辆102仪表板112中的HVAC排气口110。气道104的另一端还包括一压力通气口114和一焊接凸缘116，如图所示，凸缘116靠近压力通气口114，并从其延伸出。压力通气口114具有一开口118，其经过顶衬106上的对应开口通入到车辆102的载客室中。
气道104通过振动焊或超声焊接合到顶衬106上。将气道104振动焊接到顶衬106的方式类似于上述的过程。
图11表示了位于振动焊设备20(见图3)中的气道104和顶衬106。图3和图10中共同的元件将用相同的数字标号指代，且仅对二者的差异之处进行描述。气道104的适当部位—例如压力通气口114和焊接凸缘116被放置到一个夹具120中。然后将顶衬106放置到夹具120中，使其位于夹具120中气道104部分的上方，并使顶衬106的可视面(纤维层16)面朝上。
然后启动振动焊设备20的焊接作业循环。工作台30抬高动作缸28和压力区32，将顶衬106顶入到上压具24中，且压力区32将焊接凸缘116紧压到顶衬106上。如果顶衬106不是能量管理系统—例如能量管理系统8的部件，则然后将焊接凸缘116压紧在顶衬106的背衬层上，如背衬层14(见图1)那样，图中所示的顶衬106背衬层为聚丙烯或聚酯背衬层。如果顶衬106为例如能量管理系统8的能量管理系统的部件，则焊接凸缘116或者是被紧压到能量管理系统的防震垫上—例如防震垫18(见图1)，或者被紧压到顶衬106的聚酯背衬层上，这取决于气道104的焊接凸缘在什么部位被接合到能量管理系统8上。
当顶衬106或能量管理系统8(如可能出现的情况那样)和气道104被抬高到上压具24中时，夹具120被降低。然后启动振动头22，将气道104的焊接凸缘116压到顶衬106的背衬层或能量管理系统8的防震垫18上进行振动，如可采用的那种方式：顶衬106是能量管理系统8的一个部件。这样的振动会将气道104的焊接凸缘焊接到顶衬106的背衬层或能量管理系统8的防震垫18上。粗糙处理后的嵌入件36被放置到上压具24中，从而当顶衬106或能量管理系统8被升高到上压具24中时，嵌入件能与气道104的焊接凸缘116相对置。在完成了振动焊作业循环后，振动焊设备20以一定的压力将焊接凸缘116压紧在顶衬106或防震垫18上，并保持适当的时间。在经过了保持时间之后，工作台30下降，并将制成的气道/顶衬组件100从振动焊设备20中取出。
如上文讨论的那样，气道104一般是用聚乙烯或聚丙烯材料制成的。示例性地，顶衬106的背衬层为聚丙烯或聚酯的背衬层。同样如上文讨论的那样，能量管理系统8的防震垫18为聚丙烯蜂窝板。如上文讨论的那样，聚丙烯、聚乙烯以及聚酯为适于用振动焊进行连接的材料。但是，如果顶衬106的背衬层是由与气道104材质不适配的材料制成的，则就要按照上述的方式，在顶衬106和气道104之一或二者上都粘接一层适配材料(如上文讨论的材料)，以允许顶衬106和气道104能用振动焊的方法连接到一起。如果防震垫18是用与气道104所用材质不适配的材料制成的，则同样也可以这样来进行处理。
参见图12，对本发明的另一个方面进行描述。图10和图11中相同的元件将用相同的数字标号进行指代。在本发明的这一方面，顶衬106和气道104是通过超声焊连接到一起的。如图11所示，顶衬106以通常方式被固定到超声波焊机202中。气道104也被固定在超声波焊机202中，从而使焊接凸缘116抵压着顶衬106上连接气道104的部位。将超声焊机200的焊头202与气道104的焊接凸缘118相接触，并启动超声焊机200。这将会把气道104的焊接凸缘116用超声波焊接到顶衬106的背衬层上。作为备选方案，顶衬106可以是能量管理系统的部件，其中的能量管理系统例如为能量管理系统8(见图3)。在此情况下，气道104的焊接凸缘116平抵着防震垫18与顶衬106背衬层二者中的至少之一，并被超声焊接到此结构上。
示例性的超声焊机200可以是由康奈提格州Danbury地方的Branson Ultrasonics出品的一种超声波点焊机。
应当指出的是：图10-12中所示气道104的构造是示例性的，气道104也可以采用其它的结构。
如所公知的那样，为了能将两种材料用超声波焊接到一起，它们应当是“相适配”的，此概念与上文针对振动焊所描述的含义是非常一致的。也就是说，这两种材料必须要具有相近的熔点和类似的分子结构。在此方面，当气道104是由聚丙烯材料制成时，顶衬106的背衬层示例性地为聚丙烯材料。在气道104是由聚丙烯材料制造的情况下，背衬层也可以是用聚酯材料制成的，但这将会形成机械接合或局部接合，而不会有完全均质的接合。
对于由“不适配”材料制成的部件，通过将用“相适配”材料制成的一个材料层粘接(例如是用粘接剂)到其中一个部件或全部两个部件上。在此处，“相适配”材料是指这样的材料：其可被超声焊接到另一个部件或由可适配材料制成的另一层(如可能出现的情况那样)上。图13中的图表表示了对于超声焊接各种材料之间的适配性。图13中的图表将适配性描述为能使材料完全融合，从而形成均质的接合。可用其它组成成分的材料来形成机械接合或局部性的接合。
为了将不适配的材料(例如为聚丙烯)用超声波焊接方法焊接到图13中所示的、与聚丙烯不适配的材料上，可在用不适配材料制成的部件的表面上粘接一层可适配的材料—例如聚丙烯薄层。然后，通过对这两个部件执行超声波焊接，从而将粘接到非适配材质的部件上的聚丙烯材料层用超声焊接方法连接到由聚丙烯材料制成的部件上，这样就可将由非适配材料制成的部件焊接到由聚丙烯材料制成的部件上。在这一点上，与仅对一个部件进行处理相反，也可先在两部件的表面上都粘接例如为聚丙烯的适配材料层。只要顶衬106和气道104是用不适于用超声波焊接连接到一起的材料制成的，就可以有利地应用上述的方法来将顶衬106和气道104用超声焊接连接起来。
在本质上而言，本发明的描述仅是示例性的，因而，不偏离本发明要旨的改动应当是在本发明的保护范围内。这样的改动不应当被看作是悖离本发明的设计思想和保护范围。

Claims (32)

1.一种用于将塑料气道接合到车辆顶衬上的方法，其包括步骤：用振动焊方法将气道的至少一个部分焊接于顶衬的至少一个部分上。
2.根据权利要求1所述的方法，其特征在于：所述气道包括至少一个焊接凸缘，且将气道的至少一个部分用振动焊方法焊接于顶衬的至少一个部分上的过程，包括用振动焊方法将焊接凸缘的至少一个部分焊接到顶衬的至少一部分上的步骤。
3.根据权利要求2所述的方法，其特征在于：至少气道的焊接凸缘是用聚乙烯和聚丙烯中的一种制成的，且顶衬上至少一个部分是用聚酯和聚丙烯中的一种材料制成的。
4.根据权利要求3所述的方法，其特征在于：所述顶衬上的至少一个部位是指顶衬的背衬层上的一个部分。
5.根据权利要求1所述的方法，其特征在于：顶衬是一能量管理系统的部件，该能量管理系统包括所述顶衬以及粘接到顶衬上的防震垫，用振动焊方法将气道的至少一个部分焊接到防震垫与顶衬背衬层二者中至少之一的至少一个部分上。
6.根据权利要求2所述的方法，其特征在于：顶衬是一能量管理系统的部件，该能量管理系统包括所述顶衬以及粘接到顶衬上的防震垫，气道的焊接凸缘被用振动焊方法焊接到防震垫与顶衬背衬层二者中至少之一的至少一个部分上。
7.根据权利要求6所述的方法，其特征在于：焊接凸缘是用聚乙烯与聚丙烯中的一种材料制成的，且防震垫是用聚丙烯材料制成的。
8.根据权利要求4所述的方法，其特征在于：焊接凸缘与背衬层是由互不适配的材料制成的，所述方法还包括步骤：在执行将焊接凸缘的至少一个部分用振动焊方法连接到背衬层的至少一个部分的步骤之前，先在要执行振动焊的焊接凸缘与背衬层之一的至少所述部分上粘接一适配材料层，该材料可与焊接凸缘与背衬层中另一个的材料相适配。
9.根据权利要求6所述的方法，其特征在于：焊接凸缘的至少一个部分被用振动焊方法焊接到防震垫的至少一个部分上，且焊接凸缘与防震垫是由互不适配的材料制成的，所述方法还包括步骤：在执行将焊接凸缘的至少一个部分用振动焊方法连接到防震垫的至少一个部分的步骤之前，先在要执行振动焊的焊接凸缘与防震垫之一的至少所述部分上粘接一适配材料层，该材料可与焊接凸缘与防震垫中另一者的材料相适配。
10.一种顶衬与气道组件，其包括：用振动焊连接到一起的一顶衬及一塑料气道。
11.根据权利要求10所述的顶衬与气道组件，其特征在于：气道具有一焊接凸缘，其被振动焊接到顶衬上。
12.根据权利要求11所述的顶衬与气道组件，其特征在于：顶衬包括一背衬层，气道的焊接凸缘被振动焊接到顶衬的背衬层上。
13.根据权利要求12所述的顶衬与气道组件，其特征在于：气道的焊接凸缘是由聚乙烯和聚丙烯之一的材料制成的，且顶衬的背衬层是由聚丙烯和聚酯中的一种材料制成的。
14.根据权利要求10所述的顶衬与气道组件，其特征在于：顶衬是一能量管理系统的部件，该能量管理系统包括所述顶衬以及一防震垫，气道被用振动焊方法焊接到防震垫与顶衬背衬层二者中至少之一上。
15.根据权利要求11所述的顶衬与气道组件，其特征在于：顶衬是一能量管理系统的部件，该能量管理系统包括所述顶衬以及一防震垫，气道的焊接凸缘被用振动焊方法焊接到防震垫与顶衬背衬层二者中至少之一上。
16.一种用于将塑料气道接合到车辆顶衬上的方法，其包括步骤：用超声焊方法将气道的至少一个部分焊接于顶衬的至少一个部分上。
17.根据权利要求16所述的方法，其特征在于：所述气道包括至少一个焊接凸缘，且将气道的至少一个部分用超声焊方法焊接于顶衬的至少一个部分上的过程包括用超声焊方法将焊接凸缘的至少一个部分焊接到顶衬的至少一部分上的步骤。
18.根据权利要求17所述的方法，其特征在于：至少气道的焊接凸缘是用聚乙烯和聚丙烯中的一种制成的，且顶衬上至少一个部位是用聚酯和聚丙烯中的一种材料制成的。
19.根据权利要求18所述的方法，其特征在于：所述顶衬上的至少一个部位是指顶衬的背衬层上的一个部分。
20.根据权利要求16所述的方法，其特征在于：顶衬是一能量管理系统的部件，该能量管理系统包括所述顶衬以及粘接到顶衬上的防震垫，用超声焊方法将气道的至少一个部分焊接到防震垫与顶衬背衬层二者中至少之一的至少一个部分上。
21.根据权利要求17所述的方法，其特征在于：顶衬是一能量管理系统的部件，该能量管理系统包括所述顶衬以及粘接到顶衬上的防震垫，气道焊接凸缘的至少一个部分被用超声焊方法焊接到防震垫与顶衬背衬层二者中至少之一的至少一个部分上。
22.根据权利要求21所述的方法，其特征在于：焊接凸缘是用聚乙烯与聚丙烯中的一种材料制成的，且防震垫是用聚丙烯材料制成的。
23.根据权利要求19所述的方法，其特征在于：焊接凸缘与背衬层是由互不适配的材料制成的，所述方法还包括步骤：在执行超声焊之前，先在焊接凸缘与背衬层之一的至少一个部分上粘接一适配材料层，该材料可与焊接凸缘与背衬层中另一个的至少一个部分相适配。
24.根据权利要求21所述的方法，其特征在于：焊接凸缘与防震垫用超声焊方法焊接到一起，且焊接凸缘与防震垫是由互不适配的材料制成的，所述方法还包括步骤：在执行超声焊之前，先在焊接凸缘与防震垫之一的至少一个部分上粘接一适配材料层，该材料可与焊接凸缘的至少一部分和防震垫中的至少一个部分相适配。
25.一种顶衬与气道组件，其包括：被超声焊接到一起的一顶衬和一气道。
26.根据权利要求25所述的顶衬与气道组件，其特征在于：气道具有一焊接凸缘，其被超声焊接到顶衬上。
27.根据权利要求26所述的顶衬与气道组件，其特征在于：顶衬包括一背衬层，气道的焊接凸缘被超声焊接到顶衬的背衬层上。
28.根据权利要求27所述的顶衬与气道组件，其特征在于：气道的焊接凸缘是由聚乙烯和聚丙烯之一的材料制成的，且顶衬的背衬层是由聚丙烯和聚酯中的一种材料制成的。
29.根据权利要求25所述的顶衬与气道组件，其特征在于：顶衬是一能量管理系统的部件，该能量管理系统包括所述顶衬以及一防震垫，气道被用超声焊方法焊接到防震垫与顶衬背衬层二者中至少之一的至少一个部分上。
30.根据权利要求26所述的顶衬与气道组件，其特征在于：顶衬是一能量管理系统的部件，该能量管理系统包括所述顶衬以及一防震垫，气道的焊接凸缘被用超声焊方法焊接到防震垫与顶衬背衬层二者中至少之一的至少一部分上。
31.一种用于将两个由不适配材料制成的部件用超声焊接方法连接起来的方法，其包括步骤：在执行超声焊接之前，先在至少一个部件上粘接一层可与另一部件相适配的适配材料。
32.根据权利要求31所述的方法，其还包括步骤：在执行超声焊接之前，先在两个部件上都粘接可与另一部件彼此相适配的适配材料层。
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