CN1680089A - 振动熔接装置及其熔接方法 - Google Patents

振动熔接装置及其熔接方法 Download PDF

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CN1680089A
CN1680089A CNA2004100557280A CN200410055728A CN1680089A CN 1680089 A CN1680089 A CN 1680089A CN A2004100557280 A CNA2004100557280 A CN A2004100557280A CN 200410055728 A CN200410055728 A CN 200410055728A CN 1680089 A CN1680089 A CN 1680089A
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木村正孝
仙石大祐
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Ito Naruhiko
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    • 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
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    • 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
    • B29C65/0681—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 created by a tool
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    • B29C66/302—Particular design of joint configurations the area to be joined comprising melt initiators
    • B29C66/3022—Particular design of joint configurations the area to be joined comprising melt initiators said melt initiators being integral with at least one of the parts to be joined
    • B29C66/30223—Particular design of joint configurations the area to be joined comprising melt initiators said melt initiators being integral with at least one of the parts to be joined said melt initiators being rib-like
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    • 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
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    • B29C66/73921—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 characterised by the materials of both parts being thermoplastics
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
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    • B29C66/83221—Joining or pressing tools reciprocating along one axis cooperating reciprocating tools, each tool reciprocating along one axis
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Abstract

本发明提供对至少3个以上的由热可塑性材料构成的加工件以夹芯状进行振动熔接的装置与方法。本发明的振动熔接装置的特征在于，对至少3个以上的由热可塑性材料构成的加工件以夹芯状一体化地进行振动熔接，包括：通过振动装置可使第1加工件产生微小横向振动并对其进行支承的上夹具装置；及可对至少在上述第1加工件的两个面进行熔接的数个第2加工件进行支承的下夹具装置，并具备：通过升降装置使上述第2加工件在高度方向移动而与上述第1加工件排列齐整，通过滑动作动装置使上述第2加工件横向地朝上述第1加工件方向移动而使之与第1加工件接触的、可使上述下夹具装置动作的装置。

Description

振动熔接装置及其熔接方法
技术领域
本发明涉及使由热可塑性材料构成的数个加工件相对振动，通过摩擦热进行熔接的振动熔接技术领域。
背景技术
[特许文献1]日本专利特开平9-85833号公报
在该发明的实施例中，揭示了使由热可塑性材料构成的2个加工件以对面状抵接而进行振动熔接处理的技术。
[特许文献2]日本专利特开平9-151723号公报
在该发明的实施例中，揭示了对以固定侧夹具与振动侧夹具相抵接的2个加工件进行振动熔接的技术。
上述文献1、2所揭示的技术，不能对3个以上的加工件互相以夹芯状并一次地进行熔接。
本发明要解决的问题点是由连续性加工工序对3个以上的加工件进行一体化熔接的技术开发中存在困难之点。
且，在以往的该种热可塑性材料制品中，存在下述问题点。
例如，由于配设于汽车中驾驶席与助手席之间的中央杂物箱(存物箱)具有复杂的形状，若进行一体化的一次性成形加工时，需要形状复杂的模具，且存在造成成品成形不良的担心。
且，采用螺丝等连接数个加工件的方式，不仅存在因振动发生螺丝松开的担心，而且，增加了制造工时，另外还存在强度不稳定的担心。
发明内容
针对上述各种问题点，本发明希望解决的课题，如下所述。
本发明希望解决的第1个课题为，提供可对由3个以上的热可塑性材料构成的加工件进行夹芯状一体化振动熔接的装置与方法。
本发明希望解决的第2个课题为，提供可对由3个以上的热可塑性材料构成的加工件以高强度状态进行振动熔接的装置与方法。
本发明希望解决的第3个课题为，提供可高质量地、不引起制造不良地制造由热可塑性材料构成的复杂形状的成品的装置或方法。
本发明希望解决的第4个课题为，提供通过滑动稳定装置，对下夹具支架块状构件的相对移动距离及间隔进行控制，使高度方向的位置变动稳定化，从而，可提高熔接制品的质量的装置与方法。
本发明希望解决的第5个课题为，提供对下夹具支架块状构件的升降高度位置进行控制，从而提高熔接制品的质量的装置与方法。
本发明希望解决的第6个课题为，提供不需要复杂、昂贵的模具的装置与方法。
本发明希望解决的第7个课题为，提供不需金属制螺丝等异质固定手段而可使工件一体化连接，从而，不仅减少制造工时，而且，在制品废弃处理时不须分检的、可有效应用的装置与方法。
本发明希望解决的第8个课题为，提供可以用连续化制造工序对工件进行振动熔接，从而可大幅缩短制造时间的装置与方法。
为解决上述课题，采用的手段如下：
(1)一种振动熔接装置，其特征在于，该装置对至少3个以上的由热可塑性材料构成的加工件以夹芯状一体化地进行振动熔接，包括：通过振动装置可使第1加工件产生微小横向振动并对其进行支承的上夹具装置；及可对至少在上述第1加工件的两个面进行熔接的数个第2加工件进行支承的下夹具装置，并具备：通过升降装置使上述第2加工件在高度方向移动而与上述第1加工件排列齐整，通过滑动作动装置使上述第2加工件横向地朝上述第1加工件方向移动而使之与第1加工件接触的、可使上述下夹具装置动作的装置。
(2)根据上述(1)记述的振动熔接装置，其特征在于，该装置中设置有，可使左右下夹具支架块状构件同步地相对横向移动的滑动稳定装置。
(3)根据上述(1)记述的振动熔接装置，其特征在于，该装置中设置有使左右下夹具支架块状构件的相对横向移动在高度方向上稳定的滑动稳定装置。
(4)根据上述(1)记述的振动熔接装置，其特征在于，该装置中设置有可对左右下夹具支架块状构件的间隔进行控制的距离传感器。
(5)根据上述(1)记述的振动熔接装置，其特征在于，该装置中设置有对升降框的高度位置进行限制的升降控制杆及框限制件。
(6)一种振动熔接方法，其特征在于，该方法对至少3个以上的由热可塑性材料构成的加工件以夹芯状一体化地进行振动熔接，由下述各连续工序构成：
(A)加工件装设工序
在相互分离地进行配置的上夹具装置及数个下夹具装置上，分别装设第1加工件及在上述第1加工件的两侧面进行熔接处理的至少为2个的数个第2加工件。
(B)加工件抵接工序
使数个下夹具装置上升并相互接近，使上述第1加工件与第2加工件压接。
(C)振动熔接工序
通过上夹具装置，使第1加工件产生微小横向振动，在与之压接的第2加工件之间产生摩擦热，使加工件部分地发生熔融。
(D)加工件冷却工序
停止上述微小横向振动，进行自然冷却。
[发明的效果]
本发明可获得下述特有效果。
1.可对由热可塑性材料构成的3个以上的加工件进行夹芯状一体化振动熔接。
2.经振动熔接的成品具有高强度。
3.不需复杂形状的模具，可获得高质量的成品。
4.成品中不含金属构件等异质材料，废弃时不须区别回收。
5.制造工序可连续、高速化进行，提高生产效率。
附图说明
图1为本发明的最佳实施例的侧剖视图。
图2为图1的功能框图。
图3为熔接前预备工序图。
图4为工件设置工序图。
图5为下夹具装置的上升工序图。
图6为工件压接工序图。
图7为振动熔接工序图。
图8为落下防止装置的后退工序图。
图9为中央箱体的脱离工序图。
图10为左右面板的脱离工序图。
图11为中央杂物箱的取出工序图。
图12为中央杂物箱的工件立体图。
具体实施方式
以下，依据图1～图11对本发明的最佳实施例进行说明。
图1所示的振动熔接装置1000为制造配设于汽车中驾驶席与助手席之间的中央分隔兼存物器具(中央杂物箱)的具体例，其构成如下：
1.振动熔接装置1000的概要
在由固定框110及升降框120构成的框架装置100中设置有各种装置。
即，其构成为：在通过油压作动装置200进行升降的升降框120内，搭载有通过滑动作动装置300进行移动、并通过吸附装置400而能对第1加工件(中央箱体)进行保持的下夹具装置500；在固定框110上垂设有通过振动发生装置600而发生微小振动、并通过吸附装置400能对第2加工件(左右面板)进行保持的上夹具装置700，并由下述的控制装置800进行动作控制。
2.各个装置的构成
(1)上夹具装置700
在对如图12所示的构成中央杂物箱CC的中央箱体CB及左右面板LP、RP进行振动熔接加工时，如图1所示，支承中央箱体CB的上夹具装置700，从与固定框110连接设置的上夹具板710的下面呈对面状地垂设有2个上夹具支架块状构件720，其下部外侧衬垫有与中央箱体CB抵接的第1缓冲构件721，用插入中央箱体CB内的吸附装置400的箱体用真空吸杯410可保持中央箱体CB。
另外，构成为，由振动发生装置(振动器)600引起使该上夹具板710产生微小振动。
(2)下夹具装置500
以左右相对状设置于下夹具装置500的下夹具支架块状构件510、520，可在横向往复移动地搭载于升降框120上，通过下述的滑动作动装置300使之发生沿直线相对接近或分离的动作，对构成中央杂物箱CC的左右面板LP、RP进行支承的相对面上附设有第2、第3缓冲构件511、521，通过吸附装置400的左右面板用真空吸杯420、430能对左右面板LP、RP相对状进行保持。
上述滑动作动装置300，将装配于升降框120上的第1、第2气缸310、320的活塞杆311、321的外端，分别与以上下方向突出设置于左右下夹具支架块状构件510、520的基框512、522上的左右凸缘513、523连接。
此外，各基框512、522上，还连接设置有凭借小齿轮530进行连动的一组齿条514、524，另外，还夹装了使突出设置于基框512、522下面的滑块515、525与升降框120上的导轨123相卡合的滑动稳定装置560。
在左右下夹具支架块状构件510、520间设置有：在熔接作业时，对相互接近、或分离的左右下夹具支架块状构件510、520的间距进行检测的距离传感器900，例如是通过金属表面流动的涡电流的变化对距离的变化进行检测那样的传感器。
中央箱体CB的落下防止装置920，是通过将用于防止由上夹具支架块状构件720支承的中央箱体CB脱落、落下的保持板921固定于液压缸922的活塞杆923的上端的装置，可在熔接处理中稳定地保持中央箱体CB。
(3)油压升降装置200
上述升降框120与油压缸210的活塞杆211连接，当熔接处理时，使下夹具装置500发生升降动作，与升降框120连接设置的升降控制杆121在固定框110上的框限制件122的共同作用下，对升降框120的高度位置加以限制，以提高安全性。
(4)控制装置800
构成C.P.U的控制装置800，如图2地进行接线，可使各装置按来自操作指令部810的指令适时地进行动作、停止。
即，通过控制装置800，使油压升降装置200动作，由此，对升降框120进行升降控制，借助吸附装置400分别使中央箱体CB支承于上夹具支架块状构件720上及使左右面板LP、RP支承于左右下夹具支架块状构件510、520上。
另外，通过滑动作动装置300，使左右下夹具支架块状构件510、520移动并与中央箱体CB及左右面板LP、RP进行压接；通过振动发生装置600可进行振动熔接处理；通过距离传感器900可对左右下夹具支架块状构件510、520的间隔进行控制，以使熔接处理稳定化；通过框限制件122可对升降框120的高度安全地进行控制。
另外，控制落下防止装置920，可对中央箱体CB稳定地进行保持。
3.加工件
构成中央杂物箱CC的示于图12中的3个加工件，都由ABS树脂或PP材料等热可塑性材料构成。
在中央位置进行振动熔接处理的中央箱体CB呈箱形状。
在位于中央箱体CB两侧的、以夹芯状受到中央箱体CB的振动熔接处理的左右面板LP、RP上，形成有朝向中央箱体CB的、向内突出的横向平行状的熔接肋LIB。
4.振动熔接方法
以下，依据图3～图11对使用上述振动熔接装置1000进行的熔接方法的各工序进行分别说明。
(1)预备工序
如图3所示，当升降框120处于下降位置，左右下夹具支架块状构件510、520被分离地配置，并且，其上方的上夹具支架块状构件720同样被分离地配置时，进入准备状态。
(2)工件设置工序
如图4所示，在上夹具支架块状构件720中嵌装作为加工件的中央箱体CB，同时，在左右下夹具支架块状构件510、520中插入左右面板LP、RP，起动吸附装置400，用箱体用真空吸杯410及左右面板用真空吸杯420、430，分别将中央箱体CB及左右面板LP、RP吸附于上夹具支架块状构件720及左右下夹具支架块状构件510、520上，稳定地加以保持。
(3)下夹具装置500的上升工序
如图5中箭头示意，起动油压缸210，与升降框120一起地使下夹具装置500上升，直至使左右面板LP、RP到达与中央箱体CB相对的配合位置。
有关此时升降框120的上升移动量，在升降控制杆121至受到框限制件122限制于停止位置前，可安全地上升。
另外，使与落下防止装置920的液压缸922的活塞杆923连接的保持板921上升(箭头B)，从下面对中央箱体CB进行支承，防止落下。
(4)工件压接工序
如图6中所示，使第1、第2气缸310、320的活塞杆311、321按箭头方向动作，使左右下夹具支架块状构件510、520向相互接近的方向移动，使左右面板LP、RP夹芯状地夹住中央箱体CB，熔接肋LIB处于受到压接的状态。
此时，因在各活塞杆311、321间夹装了滑动稳定装置560，左右下夹具支架块状构件510、520被等距离地移动。且，因导轨123及滑块515、525的作用，稳定地得到维持。
(5)振动熔接工序
如图7所示，与上夹具板710连接的振动器600，使上夹具支架块状构件720产生与纸面垂直方向的微小横向振动，使左右面板LP、RP的熔接肋LIB与中央箱体CB之间产生摩擦热，使熔接肋LIB的前端熔融，使左右面板LP、RP与中央箱体CB间进行熔接。
该作业中，用距离传感器900对依据上述熔接肋LIB的熔融量确定的熔融余量LIS的距离进行检测，同时，使第1、第2气缸310、320进行追加动作，使左右下夹具支架块状构件510、520略微地(约3mm左右)接近，以促进熔接处理的进行。
(6)冷却工序
在上述工序(5)的状态下，在距离传感器900信号指令下，控制装置使振动器600停止，在短暂的期间(约3秒左右)内，保持其位置，等待冷却、硬化。
(7)落下防止装置920的后退工序
如图8中箭头所示方向，使保持板921下降，使之与中央箱体CB的下面分离。
(8)中央箱体CB的脱离工序
如图9所示，停止吸附装置400的箱体用真空吸杯410的动作，同时，使升降框120下降，使上夹具支架块状构件720与中央箱体脱离。
(9)左右面板LP、RP的脱离工序
如图10所示，停止吸附装置400的左右面板用真空吸杯420、430的动作，同时，使第1、第2气缸310、320向箭头方向逆进，使左右面板LP、RP从左右下夹具支架块状构件510、520脱离。
(10)中央杂物箱CC的取出工序
如图11所示，将经上述各工序而形成的中央杂物箱CC从振动熔接装置1000取出，结束所有工序。
[实施例]
振动熔接作业实施例的各参数条件，如下所述。
1.微小振动频率：100Hz～240Hz
2.对加工件的加压力：约50～1000kg
3.熔融余量：约3mm
4.熔融时间：约3sec
5.冷却时间：约3sec
加工件如下所述。
1.原材料
ABS树脂、丙烯酸树脂、聚碳酸酯、聚乙烯、聚丙烯。
2.尺寸
中央箱体的厚度：约2～5mm
左右面板的厚度：约2～5mm
[产业上利用的可能性]
本发明可精简制造工序，制得由复杂形状的热可塑性材料构成的成品。并且，可尽力使成品紧凑化，同时可使其刚性增大，因可适用于各种塑料制品，其在产业上能利用的可能性极大。

Claims (6)

1.一种振动熔接装置，该装置对至少3个以上的由热可塑性材料构成的加工件以夹芯状一体化地进行振动熔接，其特征在于，包括：通过振动装置可使第1加工件产生微小横向振动并对其进行支承的上夹具装置，及可对至少在上述第1加工件的两个面进行熔接的数个第2加工件进行支承的下夹具装置，并具备：通过升降装置使上述第2加工件在高度方向移动而与上述第1加工件排列齐整，通过滑动作动装置使上述第2加工件横向地朝上述第1加工件方向移动而使之与第1加工件接触的、可使上述下夹具装置动作的装置。
2.根据权利要求1所述的振动熔接装置，其特征在于，该装置中设置有可使左右下夹具支架块状构件同步地相对横向移动的滑动稳定装置。
3.根据权利要求1所述的振动熔接装置，其特征在于，该装置中设置有，使左右下夹具支架块状构件的相对横向移动在高度方向上稳定的滑动稳定装置。
4.根据权利要求1所述的振动熔接装置，其特征在于，该装置中设置有可对左右下夹具支架块状构件的间隔进行控制的距离传感器。
5.根据权利要求1所述的振动熔接装置，其特征在于，该装置中设置有对升降框的高度位置进行限制的升降控制杆及框限制件。
6.一种振动熔接方法，该方法对至少3个以上的由热可塑性材料构成的加工件以夹芯状一体化地进行振动熔接，其特征在于，由下述各连续工序构成：
(A)加工件装设工序
在相互分离地进行配置的上夹具装置及数个下夹具装置上，分别装设第1加工件及在上述第1加工件的两侧面进行熔接处理的至少为2个的数个第2加工件。
(B)加工件抵接工序
使数个下夹具装置上升并相互接近，使上述第1加工件与第2加工件进行压接。
(C)振动熔接工序
通过上夹具装置，使第1加工件产生微小横向振动，在与之压接的第2加工件之间产生摩擦热，使加工件部分地发生熔融。
(D)加工件冷却工序
停止上述微小横向振动，进行自然冷却。
CNB2004100557280A 2004-04-08 2004-08-02 振动熔接装置及其熔接方法 Expired - Fee Related CN100519152C (zh)

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CN102896771A (zh) * 2012-09-25 2013-01-30 东莞井上建上汽车部件有限公司 一种塑胶件振动熔接工艺
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CN100448590C (zh) * 2006-12-29 2009-01-07 西北工业大学 线性摩擦焊机摩擦压力加载机构
CN102529088A (zh) * 2010-04-16 2012-07-04 昆山市创新科技检测仪器有限公司 圆形热塑性塑料熔接设备及方法
CN102896771A (zh) * 2012-09-25 2013-01-30 东莞井上建上汽车部件有限公司 一种塑胶件振动熔接工艺
CN105415667A (zh) * 2014-09-17 2016-03-23 丰田自动车株式会社 构造成包括热塑性树脂材料的构件的制造方法和制造装置

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