CN1652928A - 具有使工件可焊接的吸收剂染料的表面沉积物的预处理工件 - Google Patents

具有使工件可焊接的吸收剂染料的表面沉积物的预处理工件 Download PDF

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CN1652928A
CN1652928A CNA038022605A CN03802260A CN1652928A CN 1652928 A CN1652928 A CN 1652928A CN A038022605 A CNA038022605 A CN A038022605A CN 03802260 A CN03802260 A CN 03802260A CN 1652928 A CN1652928 A CN 1652928A
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workpiece
polymer
welding
dye
dyestuff
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CN100439093C (zh
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S·M·哈特利
R·A·萨拉范蒂
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Gentex Corp
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Gentex Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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    • B29C65/168—Laser beams making use of an absorber or impact modifier placed at the interface
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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  • Health & Medical Sciences (AREA)
  • Electromagnetism (AREA)
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Abstract

一种可焊接的工件(16)，通过在工件表面上沉积拥有较强吸收和强调消光系数的吸收剂染料(20)而制备。该染料以均匀的密度沉积，从而具有这样的容量，能够通过电子振动松弛和放热分解而将约0.1焦每平方毫米的内部辐射能量转化成热能。在光学应用中，工件形成具有高光象和光学传导率的焊缝。一种处理工件的方法描述了用于选择聚合物、染料和载体的方法。

Description

具有使工件可焊接的吸收剂染料的 表面沉积物的预处理工件
技术领域
本发明涉及一种具有吸收剂染料的表面沉积物的预处理工件，该吸收剂染料用于在未来焊接过程中消耗的明确目的。更特别地，本发明涉及设计和制造用于在辐射过程中优良能量转化效率的工件的机械和化学特性。
背景技术
例如从美国专利5893959中可知道通过穿透传导激光焊接接合塑料部件。美国专利5893959中使用颜料来提高沿焊接区域的吸收性能。但由于所公开的颜料在焊接过程之后存留下来，它们不受欢迎地影响了接点的外观。该专利通过在接合之前和之后将颜料加入上下基体的整体中来补偿降低的美观性。上基体被描述为具有小于1％的颜料浓度，在焊接激光波长下其可提供大于60％的传导率。下基体接收1-2％的颜料浓度，产生可忽略的传导率。
因此会需要限定可焊接的工件的设计标准和制造特性的范围，它能够：在接点提供最小的阻塞，可进一步在接点具有可视的，甚至是光学的透明度；仅有选择地将吸收剂沉积在焊接区域上，从而消除在整体残留物中由吸收剂引起的阻塞；以这样的方式加入染料，使它们分解成惰性、可溶解的不可见副产品；使用主要影响在焊接波长下的传导率的吸收剂染料；使用在数字上与焊接波长间隔开的波长下影响传导率最小的吸收剂染料；使用在可见光光谱范围内影响传导率最小的吸收剂染料；在某些实施例中，在可见光光谱范围内对传导率没有影响甚至有有益影响。
在Russek的名称为Laser Beam Welding of Polymers with HighPower Diode Lasers：Joining Innovation for Micro and MacroTechnologies(用高能二极管激光器进行的聚合物的激光束焊接：微观和宏观技术革新的结合”的论文中将使用碳墨颜料和吸收剂染料的应用之间的关系描述为线能量的函数。该论文提出了设计模型来解决焊接过程中间隙桥接问题的三维、立体热动力工艺。这种方式的一个显著缺点在于，如图6中所示，焊缝必须是完整的并剖开截面来获得能量密度分布。Russek没有在单一工件上的染料密度，也没有建议对应于表面染料沉积的固有容量的每单位面积能量范围。国际申请号为PCT/GB99/03241的已公开PCT申请公开了一种工艺，用于焊接其间夹着红外吸收剂染料的焊接部件。
发明内容
因此需要确定制备聚合物工件的基本要求，从而能够灵活地将其焊接到另一个自由选择部件上。
因此本发明的一个目的是提出这种聚合物工件的最小机械和化学要求。
本发明的另一个目的是提出在理想条件下这种工件的光学传导特性。
本发明的又一个目的是提出在工件上形成电磁辐射能量导控器的方法。
根据本发明，这些和其它相关目的是通过其第一实施例实现的，它涉及用于工件的机械和化学要求。
一种可焊接的工件，它具有由第一聚合物制成的表面，该第一聚合物在加热时(或后)软化而适于熔合到一种材料上，该材料在加热时(或后)软化并可从第二聚合物自由选择，该第二聚合物与第一聚合物相同或相似，或者是至少易于与第一聚合物的表面局部相互混合的不同聚合物，其中第一聚合物和可自由选择的第二聚合物具有重叠的熔化温度范围。该工件具有一个延伸经过一个散装部分的表面。一个在辐射能量源的焊接波长下拥有较强的吸收和较高的消光系数的吸收剂染料沉积在上述工件表面上或上方，从而借助于一个载体限定了一个焊接区域，该载体具有必要的粘度，并可避免与焊接区域发生不适当的干涉或阻塞。上述沉积物包括每平方毫米约5至约3000毫微克染料的大致均匀的密度，以提供可预测和前后一致的加热，从而使上述工件可焊接。该焊接区域具有这样的容量，能够借助于在将至少一部分上述染料放热分解成惰性不可见副产品之后紧随的电子振动松驰而将在上述焊接波长下约0.1焦/平方毫米的内部辐射能量转换成热能，它们的组合能够输送(I)在上述散装部分方向上导向的第一热能量而将上述表面提升到上述表面的熔化温度范围，以及(II)在相反方向上导向的接近相等的热能量离开上述散装部分。上述染料、上述载体、上述副产品以及上述第一聚合物的上述表面都是可相互混合的。上述工件以及任何薄膜可由热塑聚合物制成。染料可以是可见光吸收染料，近红外吸收染料，或者它们的组合。如果载体是液体溶剂，它必须能够溶解吸收剂染料以提供均匀的表面密度。如果液体载体在表面下面释放吸收剂染料，它应当到达足够小的深度，以避免在焊接过程中发泡。在液体溶剂中，吸收剂染料存在于约1×10-2至约1-10-4克每毫升的浓度中，从而在溶剂蒸发后所述的表面沉积物密度范围内释放染料。
根据本发明，这些和其它相关目的通过其第二实施例实现，它涉及工件的光学特性。
一种传导增强制剂(或配方)，该制剂设置于具有第一散装部分的第一辐射能量传导工件的第一反射表面与具有第二散装部分的第二工件的第二反射表面之间。两个反射表面都由加热时软化的聚合物材料制成，其中以辐射能量源的焊接波长沿穿过制剂和散装部分以及反射表面的光路的传导率低于仅穿过散装部分和反射表面的光学传导率。第一和第二反射表面由具有重叠的熔化温度范围的聚合物制成，该传导增强制剂包括一个包含辐射能量吸收染料的材料系统，该染料具有与辐射能量源的焊接波长相匹配的吸收带。上述材料系统能够通过连续的电-热和化学-热转化活动而将属于制剂的上述较低的光传导率导引成热能，其中上述热能可传送到设置在与上述材料系统相同的光路中的反射表面中。上述热能传送能够将传导减小反射表面一起焊接到一个传导增强区域中，该传导增强区域具有光学熔合在一起的散装部分。
该传导增强区域在可见光谱范围内呈现出的光传导率大于仅通过这些部分和反射表面的传导率。该传导增强区域在可见光谱范围内的经选择的波长下呈现出的光传导率大约比仅通过这些部分和反射表面的传导率大10％，或者大1.1倍。
该传导增强区域呈现出的光象传导率比仅通过这些部分和反射表面的光象传导率大约10％，或者大1.1倍。沿光路穿过制剂的光传导率大约比通过这些散装部分和反射表面的光传导率低10％，或者低0.9倍。该材料系统可与上述反射表面相互混合，从而避免阻塞传导增强区域。可相互混合性是由上述染料、上述载体、上述副产品和上述反射表面的Hansen可溶性参数的数字近似来测量的。上述数字近似的Hansen可溶性因数能够使传导增强区域中光传导的阻塞最小。
根据本发明，这些和其它相关目的通过其第三实施例实现，它涉及在工件上形成辐射能量导控器。
一种对由第一聚合物制成的工件进行预处理的方法，用于制备它用于一个高效穿透传导辐射可焊接操作的唯一目的，该操作将工件熔合到由一种材料制成的配合板上，该材料在加热时软化并可从第二聚合物自由选择，该第二聚合物与第一聚合物相同或相似，或者是至少易于与第一聚合物的表面局部相互混合的不同聚合物，其中聚合物具有重叠的熔化温度范围。在第一步骤中，形成一个基本上以层状焊接区域形式的辐射能量导控器。成形包括下列步骤：(I)选择一第一聚合物，该第一聚合物在加热时软化，并包括一个散装部分和一个延伸经过该散装部分的表面，(II)选择一种染料，该染料在辐射能量源的焊接波长下具有较强的吸收和较高的消光系数，(III)选择一个染料载体，该载体具有足够的粘度从而限定焊接区域的边缘，并避免不适当地干涉焊接操作或阻塞最终熔合部分，以及(IV)通过该染料载体将每平方毫米5至3000毫微克的染料沉积在工件表面上或上方。上述辐射能量导控器的容量能够根据下列步骤在焊接操作过程中完成电、化学和机械转化：(1)借助于电子振动松驰将在上述焊接波长下约0.1焦/平方毫米的内部辐射能量转换成热能，(2)在紧随上述转化步骤之后将至少一部分上述染料放热分解成惰性不可见副产品，以及(3)在上述转化和分解步骤中，将第一能量释放到散装部分中，将该表面提升到第一聚合物的熔化温度范围，并在相反方向将大致相等的第二量的能量释放离开上述散装部分。
从下面结合附图所作的详细描述中，将明白本发明的其它目的和特征。但可以理解，设计附图仅是为了示意的目的，而不是对本发明的限制的定义，本发明应当参照附属权利要求。还应当理解，这些附图并不是必然按照比例画出的，且除非另有提示，它们仅是在概念上表示这里所述的结构和程序。
附图说明
在附图中的全部视图中，相同的附图标记表示相似的部件：
图1是根据本发明的预处理工件的透视图，具有一个沿其一侧的吸收剂染料表面沉积；
图2A是沿图1中线II-II所取的表面沉积的放大剖视图；
图2B是沿图1中的线II-II所取的表面沉积另一个实施例的放大剖视图；
图3是一个图表，表示在工件预处理过程中各阶段的传导率曲线，以及在电磁辐射之后的传导率曲线；以及
图4是工件和相配材料的多部件剖视图，表示对应于图3中每个曲线的条件。
具体实施方式
现在参照附图，特别是图1，示出一个制备的工件10，该工件10设计用于在任何未来时间焊接到由兼容的聚合物制成的材料上的明确和最终目的。换句话说，工件10可以认为是流程中加工，其中对工件进行一些初始加工，并可保留在库存中一段较长时间，等待进一步的加工。本专利申请将覆盖工件的设计和工程特征，它适于通过将表面层共同加热到它们各自的熔化温度范围直到这些部件熔化并熔合在一起而粘结到一种材料上。虽然不是本申请的特定部分，但焊接过程由穿透传导辐射能量焊接构成。这种辐射能量可由大量能量源提供，包括在可见、近红外和红外光谱工作的激光器，以及红外灯和红外发射体。尽管激光器的带宽一般窄于红外灯，但这里使用的术语“焊接波长”表示吸收器和辐射能量源为释放热焊接能而共同具有的一个或多个波长。
工件和相配材料匹配性
一般来讲，根据本发明的工件是由热塑材料或小组的热固塑料制成的。还包括由塑料或塑料纤维或者具有塑料涂层的其它纤维制成的织物组织。本发明的工件设计能够将其表面熔合到一个配合表面上，在与该表面相邻的每个方向影响若干聚合物层。主要特征在于，至少工件的表面在加热时软化，而不是分解。相似地，配合表面应当在加热时软化。工件和适于焊接到其上的相配材料应当是易相互混合的聚合物，且应当具有重叠的熔化温度范围。
工件，染料及相关化学成分相容性
尽管吸收剂染料可以如带或膜的固态形式置于工件表面上，但特殊的应用效果是由于液态形式涂抹而获得的。尽管涂抹工艺不是本发明的一部分，但所产生的工件不应当由于提到有限数量的涂抹工艺而以任何方式被限制，因为由涂抹工艺赋予的特征可以由多种涂抹工艺实现。例如，对于多种表面、形状、工件类型、期望用途及其组合来讲，液体分配或者喷墨打印分别提供不同方面的柔韧性、成本效率和涂抹均匀性。
对于液体形式涂抹，需要一种基本上溶解染料而形成油墨的溶剂。工程要求包括油墨的正确粘度、表面张力和印染时间，它们全都能够影响如何良好限定焊接区域的边缘。在溶剂蒸发后，染料以及填加剂、溶剂残留物和污染物一起保留在表面上。相似地，对于固态形式的涂抹，染料与构成膜或带的其它构成物一起设置在表面上。如下面更详细描述的，染料在焊接过程中会分解。因此要求填加剂、残留物、污染物、其它构成物、染料、分解产品以及涂抹工艺的其它副产品，全部易于混合在工件和相配材料的表面聚合物中。还要求这些成分中没有哪一个例如由于热沉或不匹配熔化温度而干扰焊接过程，或者阻塞最终的焊接。
这些染料是在焊接波长下具有较高吸收和较大消光系数的可见光吸收、近红外(NIR)吸收或者红外(IR)吸收染料。与此同时，染料在激光波长以外的范围内，特别是在可见光光谱范围内，应当具有较低的吸收和较低的染色。
在本发明的一个实施例中，将一个可见光吸收染料与匹配的可见光传导激光器一起使用。可替换地，将NIR吸收染料与NIR激光器一起使用。也可使用其它可见、NIR或IR辐射能量。尽管激光器在单一波长下工作，但IR灯和IR发射体可在多个波长下工作。可使用染料的组合来跨越包括该多个波长的的一个带宽吸收。此外，可用一种染料的发热能量来起动第二染料的分解。不论使用的是一种还是多于一种染料，关键的要素是能量的高效转换，以及焊接的光传导成问题的低阻塞。
再次参照图1和2A，工件10包括一个代表相互作用表面层的表面16。工件10还具有一个散装部分14，它是表面16下面的散装材料，代表工件10的一个非活性部分。工件10设计和制造用于焊接到相配材料12上的唯一和最终的目的。
吸收剂染料20沿表面16沉积。染料20的存在限定了一个焊接区域22。换句话说，焊接区域22是表面16的一个能够焊接的区域。在任何未来时间都可通过正确地将相容的聚合物12放置成接触表面16并将焊接区域22暴露于本发明范围内的一定的激光能量而沿焊接区域22获得焊接。图2A表示以单独分子形式存在于表面16上的吸收剂染料，具有若干分子层的厚度。吸收剂染料溶解在适当的匹配溶剂中，并涂抹于表面16上。根据溶剂相对于工件材料的侵蚀性，溶剂会导致染料若干分子层较深地浸入表面16中。当这些表面层在焊接过程中熔化时，浸入的染料将在接合区域遇到熔化流。令人惊奇的是，申请人发现，轻微的浸入是可以接受的，只要熔化流区域随后到达这些浸入染料分子。但如果染料进一步浸入表面中，则它远离熔化流区域的加热会导致发泡，这会阻塞焊接接点。
在图2B的实施例中，由于首先将吸收剂染料加入薄膜中，然后将薄膜放到表面16上，完全避免了浸入。该实施例还避免了与染料/溶剂沿表面运行从而减弱了焊接区域的边缘锐度相关的任何问题。焊接区域的边缘代表表面16的可焊接部分与不可焊接部分之间的边界。
预处理实例
图3示出传导图形，其中曲线40是穿过放置于样本工件10顶部的样本相配材料12的传导图形。两个样本都由聚碳酸酯制成。接下来将含有1克每毫升吸收剂染料的溶液涂抹到工件10上，在其上形成一个焊接区域。曲线50是穿过放置于含有吸收剂染料的工件10顶部的相配材料的传导图形。
图4表示相配材料12位于左侧工件10位于右侧的板关系的剖视图。截面44对应于曲线40。截面55对应于曲线50，其中工件10可焊接，并代表在近红外(NIR)和红外(IR)范围内的最低传导值。
后处理实例例
再次参照图3，曲线60是在激光辐射后穿过两个板的传导图形，其中这些板没有被夹在一起，导致没有焊缝。曲线70是激光辐射后穿过两个板的传导图形，其中焊接区域面向外，导致没有焊缝。曲线80是激光辐射后穿过两个板的传导图形，其中这些板被正确定位和夹持，产生成功焊缝。
图4中，截面66对应于曲线60，截面77对应于曲线70。注意，吸收剂染料20部分或完全分解，但没有产生焊缝。测试数据显示，不正确夹持到相配材料66上的工件等同于工件77的不正确定位。在另一个测试中，制备Cyrolite丙烯酸来焊接到聚烯烃上。由于聚合物的熔化温度范围不重叠，工件不可焊接到相配材料上，从而防止相互混合的发生。截面88对应于曲线80，其中染料已经分解，工件10和相配材料12之间的反射边界已经熔合在一起。如曲线80中所示，传导降低反射边界的消除导致对于成功焊接截面88的最高传导值。
图3中，在940纳米的示例性二极管激光焊接波长下，穿过两个散装部分和两个反射表面的传导率为81.9％，对应于曲线40。引入制剂后的相同测量值为71.8％，对应于曲线50。该差值约低10％，或者约低0.9倍。对应于曲线60和70的错误焊接具有约78.4％的传导率，而对应于曲线80的正确焊接拥有86.6％的传导率。
以激光焊接波长为1064纳米的钕：钇铝石榴石为例，穿过两个散装部分和两个反射表面的传导率是81.7％，对应于曲线40。引入制剂后的相同测量值为69.1％，对应于曲线50。该差值约低10％，更具体地约低12.6％。该差值约低0.9倍，更具体地低0.8倍。对应于曲线60和70的错误焊接具有约77.5％的传导率，而对应于曲线80的正确焊接拥有86.1％的传导率。
示例性可见光谱测量波长为550纳米，它还用作光象的近似。全部曲线40、50、60和70被分组在75.3％传导率的0.3％范围内，表示在可见光谱上错误焊接之后引入和分解的最小效果。正确焊接产生83.4％的传导率。这对于在550纳米的绝对测量以及对于光象近似高约10％和高1.1倍。下
表1中概括了这些百分比传导率值。
表1
波长 曲线40截面44 曲线50截面55 曲线60截面66 曲线70截面77 曲线80截面88
1064纳米 81.7 69.1 77.5 77.5 86.1
 940纳米 81.9  71.8  78.4  78.4  86.6
 550纳米 75.3  75.3  75.3  75.3  83.4
使用不同的聚合物、不同的染料、不同的载体和不同的染料密度以及不同水平的辐射将具有不同的结果。在光学应用中，这些值是典型的。也可使用其它激光器，包括在可见光谱下工作的激光器。
表2中列出在液体载体状态下测量的7倍染料浓度的另一个例子。在较高波长下截面55的低值确认了附加染料的存在。所有其它系数保持相同。焊接后，注意与表1中的相同测量相比，尽管在截面88中存在其它波长，但截面88中具有550纳米的良好传导率。因此，该例显示部分放热分解，实际上对于可见或光象传导没有影响。在这种染料浓度下，存在附加容量，从而在本发明的参数下，在焊接过程中使用更大量的热能。
表2
 波长 截面44 截面55 截面88
 1064纳米 82.7  34.0  75.4
 940纳米 82.9  36.4  74.5
 550纳米 77.9  76.0  84.0
在另一系列测试中，通过将特殊染料喷涂到聚亚安酯而焊接到聚碳酸酯上，以及在另一种情况下喷涂到PVC上而焊接到PVC上，在高浓度下对该特殊染料进行测试。改变激光能和焊接速度以调节单位表面积的焊接能量，但不发生焊接。相信高浓度的染料及喷涂技术产生不均匀和/或超出本发明规定范围的表面密度。当以本发明规定的浓度将相同的染料均匀地加载到薄膜中时，在跨越10倍浓度的染料浓度，跨越3倍范围的薄膜厚度，跨越2.5倍范围的激光能以及跨越6.6倍范围的焊接速度下，很容易地将PMMA板焊接在一起。在单位表面积焊接能方面，该范围从0.7焦/平方毫米扩展到11.4焦/平方毫米，大于16倍范围，即6.6的2.5倍。
在本发明参数范围内进行的其它测试成功地将下面的成对材料焊接在一起：
工件                       相配材料
MDPE薄膜                   涂覆LDPE的纸板
聚丙烯薄膜                 ABA
共聚多醚                   PEN
共聚多醚                   聚丙烯
将由相同聚合物制成的工件焊接到相配材料上更容易完成，包括：聚碳酸酯，聚丙烯，PMMA，HDPE，乙缩醛，TPE，polyetherimide，PEEK，聚苯乙烯，尼龙和ABS。由于某些尼龙具有低于50％，甚至低于10％的传导率，在10％数量级上测量传导率的改变是不实际的。因此，由于即使在不透明部件的低传导率下预测的行为还在发生，1.1倍和0.9倍传导率在本发明的参数范围内很好地改变了在测量性能方面的工作。成功的焊接例如是用在下面的频谱中工作的激光完成的：钕：钇铝石榴石加倍532纳米的可见光谱，红宝石激光器694纳米和可见二极管激光器670纳米；近红外GaAs激光器；808纳米、940纳米和980纳米下的红外二极管激光器；以及钕：钇铝石榴石1064纳米。
如能够看到的，根据本发明的设计和制造参数制备的工件向最终焊接工艺提供了较高的公差和宽度。因此根据本发明制备的单一工件可在不同功率水平下灵活地与不同的焊接激光器一起使用，并与不同的配合部件一起使用。它可用于要求高强度、高正确焊接确保度以及高光学或光象传导值结合低阻塞的应用中。此外，在根据本发明制备工件的过程中，可使用很宽范围的染料和释放载体，只要遵从可溶性规则。本发明的固有灵活性与通常将部件与阻塞颜料掺杂在一起的现有技术系统相反，具有单一的颜料或染料浓度水平，或者将部件作为由相同材料制成的匹配对来处理。
因此，尽管已经图示、描述和指出了应用于本发明优选实施例的本发明的基本新颖特征，但可以理解，在不脱离本发明精神的情况下，本领域技术人员可对所描述的方法和所图示的装置在它们的应用中进行多种删除、替换和修改。例如，明确表示的是，能够以基本上相同的方式实现基本上相同的功能而达到相同结果的这些元件和/或方法步骤的全部组合都落入本发明的范围中。另外，应当认识到，结合本发明的任何公开形式或图示和/或描述的设计和制造标准、它们的构成物和/或元件和/或方法步骤，都可作为设计选择的单体事宜而引入任何其它公开或描述或建议的形式或实施例中。因此期望仅由附属于它的权利要求的范围来限定。

Claims (40)

1.一种可焊接的工件，它具有由第一聚合物制成的其表面，该第一聚合物在加热时软化而适于熔合到一种材料上，该材料在加热时软化并可从第二聚合物自由选择，该第二聚合物与第一聚合物相同或相似，或者是至少易于与第一聚合物的表面局部相互混合的不同聚合物，其中第一聚合物和可自由选择的第二聚合物具有重叠的熔化温度范围，该工件包括：
(a)所述工件具有散装部分，所述表面延伸横过所述散装部分；
(b)吸收剂染料，该吸收剂染料在辐射能量源的焊接波长下拥有较强的吸收和较高的消光系数；
所述染料沉积在所述工件表面上或上方，从而借助于载体限定焊接区域，该载体具有必要的粘度，并可避免与焊接区域发生不适当的干涉或阻塞；其中，
所述沉积物包括每平方毫米约5至约3000毫微克染料的大致均匀的密度，以提供可预测的和前后一致的加热，从而使所述工件可焊接；以及
(c)所述焊接区域具有这样的容量，能够借助于在将至少一部分所述染料放热分解成惰性不可见副产品之后紧随的电子振动松驰而将在所述焊接波长下约0.1焦/平方毫米的内部辐射能量转换成热能，它们的组合能够释放(I)在所述散装部分方向上导向的第一种热能量而将所述表面提升到所述表面的熔化温度范围，以及(II)在相反方向导向的接近相等的热能量离开所述散装部分；
其中所述染料、所述载体、所述副产品以及所述第一聚合物的所述表面都是可相互混合的。
2.如权利要求1所述的工件，其特征在于，所述工件由第一热塑聚合物制成。
3.如权利要求2所述的工件，其特征在于，该载体包括薄膜。
4.如权利要求3所述的工件，其特征在于，该载体包括热塑材料。
5.如权利要求1所述的工件，其特征在于，该载体包括薄膜。
6.如权利要求4所述的工件，其特征在于，所述薄膜包括热塑材料。
7.如权利要求1所述的工件，其特征在于，所述染料是从包括下列各项的组中选择的：可见光吸收染料，近红外吸收染料，红外吸收染料以及它们的组合物。
8.如权利要求1所述的工件，其特征在于，该载体包括溶解吸收剂染料的液体溶剂。
9.如权利要求8所述的工件，其特征在于，所述载体将所述表面下面的一部分所述吸收剂染料释放到足够小的深度，以避免在焊接过程中发泡。
10.如权利要求9所述的工件，其特征在于，所述吸收剂染料以每毫升液体溶剂约1×10-2至约1×10-4克的浓度存在，从而释放该表面沉积密度。
11.如权利要求1所述的工件，其特征在于，所述吸收剂染料在从包括下列各项的组中选择的焊接波长下拥有较强的吸收和较高的消光系数：可见光谱焊接波长，N/R焊接波长，IR焊接波长以及它们的组合。
12.一种传导增强制剂，该制剂设置于具有第一散装部分的第一辐射能量传导工件的第一反射表面与具有第二散装部分的第二工件的第二反射表面之间，其中，两个反射表面都由加热时软化的聚合物材料制成，其中，以辐射能量源的焊接波长沿穿过制剂和散装部分以及反射表面的光路的传导率低于仅穿过散装部分和反射表面的光学传导率，其中第一和第二反射表面由具有重叠的熔化温度范围的聚合物制成，其中该传导增强制剂包括：
包含辐射能量吸收染料的材料系统，该染料具有与辐射能量源的焊接波长相匹配的较强的吸收和较高的消光系数；以及
所述材料系统能够通过连续的电-热和化学-热转化活动而将属于制剂的所述较低的光传导率导引成热能，其中所述热能可传送到设置在与所述材料系统相同的光路中的反射表面中；
其中所述热能传送能够将传导减小反射表面一起焊接到传导增强区域中，该传导增强区域具有光学熔合在一起的散装部分。
13.如权利要求12所述的制剂，其特征在于，该传导增强区域在可见光谱范围内呈现出的光传导率大于仅通过这些部分和两个反射表面的传导率。
14.如权利要求13所述的制剂，其特征在于，该传导增强区域在可见光谱范围内的经选择的波长下呈现出的光传导率大约比仅通过两个部分和两个反射表面的传导率大10％。
15.如权利要求13所述的制剂，其特征在于，该传导增强区域在可见光谱范围内的经选择的波长下呈现出的光传导率大约比仅通过两个部分和两个反射表面的传导率大1.1倍。
16.如权利要求12所述的制剂，其特征在于，该传导增强区域呈现出的光象传导率大于仅通过两个部分和两个反射表面的光象传导率。
17.如权利要求12所述的制剂，其特征在于，该传导增强区域呈现出的光象传导率大约比仅通过两个部分和两个反射表面的光象传导率大10％。
18.如权利要求12所述的制剂，其特征在于，该传导增强区域呈现出的光象传导率大约比仅通过两个部分和两个反射表面的光象传导率大1.1倍。
19.如权利要求12所述的制剂，其特征在于，该材料系统可与所述第一和第二反射表面相互混合，从而避免阻塞传导增强区域。
20.如权利要求12所述的制剂，其特征在于，沿光路穿过制剂的光传导率大约比通过这些散装部分和反射表面的光传导率低10％。
21.如权利要求12所述的制剂，其特征在于，沿光路穿过制剂的光传导率大约比通过这些散装部分和反射表面的光传导率低0.9倍。
22.如权利要求12所述的制剂，其特征在于，所述染料是从包括下列各项的组中选择的：可见光吸收染料、近红外吸收染料、红外吸收染料及它们的组合。
23.如权利要求12所述的制剂，其特征在于，所述吸收剂染料在从包括下列各项的组中选择的焊接波长下拥有较强的吸收和较高的消光系数：可见光光谱焊接波长，NIR焊接波长，IR焊接波长以及它们的组合。
24.如权利要求12所述的制剂，其特征在于，化学-热转化包括将所述染料放热分解成惰性不可见副产品，其中所述染料、所述载体、所述副产品和所述反射表面是可相互混合的。
25.如权利要求24所述的制剂，其特征在于，可相互混合性包括所述染料、所述载体、所述副产品和所述反射表面的Hansen可溶性参数的数字近似。
26.如权利要求25所述的制剂，其特征在于，所述数字近似的Hansen可溶性因数能够使传导增强区域中的光传导的阻塞最小。
27.一种对由第一聚合物制成的工件进行预处理的方法，用于制备它用于一个高效穿透传导辐射可焊接操作的唯一目的，该操作将工件熔合到由一种材料制成的配合板上，该材料在加热时软化并可从第二聚合物自由选择，该第二聚合物与第一聚合物相同或相似，或者是至少易于与第一聚合物的表面局部相互混合的不同聚合物，其中，第一聚合物和可自由选择的第二聚合物具有重叠的熔化温度范围，该方法包括下列步骤：
形成一个基本上以层状焊接区域形式的辐射能量导控器，包括下列步骤：(I)选择第一聚合物，该第一聚合物在加热时软化，并包括散装部分和延伸横过该散装部分的表面，(II)选择一种染料，该染料在辐射能量源的焊接波长下具有较强的吸收和较高的消光系数，(III)选择染料载体，该载体具有足够的粘度从而限定焊接区域的边缘，并避免不适当地干涉焊接操作或阻塞最终熔合的部分，以及(IV)通过该染料载体将每平方毫米5至3000毫微克的染料沉积在工件表面上或上方；
其中，所述辐射能量导控器的容量能够根据下列步骤在焊接操作过程中完成电、化学和机械转化：(1)借助于电子振动松驰将在所述焊接波长下约0.1焦/平方毫米的内部辐射能量转换成热能，(2)在紧随所述转化步骤之后将至少一部分所述染料放热分解成惰性不可见副产品，以及(3)在所述转化和分解步骤中，将第一能量释放到散装部分中，将该表面提升到第一聚合物的熔化温度范围，并在相反方向将大致相等的第二能量释放离开所述散装部分。
28.如权利要求27所述的方法，其特征在于，所述工件由第一热塑聚合物制成。
29.如权利要求28所述的方法，其特征在于，该载体包括薄膜。
30.如权利要求29所述的方法，其特征在于，该载体包括热塑材料。
31.如权利要求27所述的方法，其特征在于，该载体包括薄膜。
32.如权利要求31所述的方法，其特征在于，所述薄膜包括热塑材料。
33.如权利要求27所述的方法，其特征在于，所述染料是从包括下列各项的组中选择的：可见光吸收染料，近红外吸收染料，红外吸收染料以及它们的组合。
34.如权利要求27所述的方法，其特征在于，所述吸收剂染料在从包括下列各项的组中选择的焊接波长下拥有较强的吸收和较高的消光系数：可见光光谱焊接波长，NIR焊接波长，IR焊接波长以及它们的组合。
35.如权利要求27所述的方法，其特征在于，该载体包括溶解吸收剂染料的液体溶剂。
36.如权利要求35所述的方法，其特征在于，所述载体将所述表面下面的一部分所述吸收剂染料输送到足够小的深度，以避免焊接后发泡。
37.如权利要求36所述的方法，其特征在于，所述吸收剂染料以每毫升液体溶剂约1×10-2至约1×10-4克的浓度出现，从而输送该表面沉积密度。
38.如权利要求27所述的方法，其特征在于，化学-热转化包括将所述染料放热分解成惰性不可见副产品，其中所述染料、所述载体、所述副产品和所述反射表面是可相互混合的。
39.如权利要求38所述的方法，其特征在于，可相互混合性包括所述染料、所述载体、所述副产品和所述反射表面的Hansen可溶性参数的数字近似。
40.如权利要求39所述的方法，其特征在于，所述数字近似的Hansen可溶性因数能够使传导增强区域中光传导的阻塞最小。
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