DE10160496A1 - Sonotrode for an ultrasonic welding system - Google Patents

Sonotrode for an ultrasonic welding system

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Publication number
DE10160496A1
DE10160496A1 DE10160496A DE10160496A DE10160496A1 DE 10160496 A1 DE10160496 A1 DE 10160496A1 DE 10160496 A DE10160496 A DE 10160496A DE 10160496 A DE10160496 A DE 10160496A DE 10160496 A1 DE10160496 A1 DE 10160496A1
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DE
Germany
Prior art keywords
sonotrode
welding
pin
contact surface
tip
Prior art date
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.)
Ceased
Application number
DE10160496A
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German (de)
Inventor
Gerhard Schmidt
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.)
Plastic Omnium Automotive Exteriors GmbH
Original Assignee
Dynamit Nobel Kunststoff GmbH
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Publication date
Application filed by Dynamit Nobel Kunststoff GmbH filed Critical Dynamit Nobel Kunststoff GmbH
Priority to DE10160496A priority Critical patent/DE10160496A1/en
Priority to PT02007443T priority patent/PT1250996E/en
Priority to AT02007443T priority patent/ATE328721T1/en
Priority to DE50207058T priority patent/DE50207058D1/en
Priority to EP02007443A priority patent/EP1250996B1/en
Priority to ES02007443T priority patent/ES2266335T3/en
Priority to US10/126,524 priority patent/US6776323B2/en
Publication of DE10160496A1 publication Critical patent/DE10160496A1/en
Ceased legal-status Critical Current

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Classifications

    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/006—Preventing damaging, e.g. 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
    • 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
    • B29C66/50—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
    • B29C66/61—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
    • B29C66/73—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
    • 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
    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81433—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined being toothed, i.e. comprising several teeth or pins, or being patterned
    • 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
    • B29C66/23—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations
    • B29C66/232—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations said joint lines being multiple and parallel, i.e. the joint being formed by several parallel joint lines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products
    • B29L2009/005—Layered products coated
    • B29L2009/006—Layered products coated painted
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3044—Bumpers

Abstract

Die Erfindung betrifft eine Sonotrode für eine Ultraschall-Schweißanlage mit einem Ultraschall-Generator, der hochfrequente elektrische Energie an einen Konverter leitet, dieser die Energie in mechanische Schwingungen umwandelt und gegebenenfalls über einen Booster an eine Sonotrode (2) leitet, wobei die Sonotrode (2) mit einer Kontaktfläche (3) ausgebildet ist. DOLLAR A Zur Vermeidung störender Einfallstellen wird vorgeschlagen, dass auf der Kontaktfläche (3) Zapfen (1) angeordnet sind.The invention relates to a sonotrode for an ultrasound welding system with an ultrasound generator that transmits high-frequency electrical energy to a converter, which converts the energy into mechanical vibrations and, if necessary, conducts it to a sonotrode (2) via a booster, the sonotrode (2 ) is formed with a contact surface (3). DOLLAR A To avoid annoying sink marks, it is proposed that pins (1) are arranged on the contact surface (3).

Description

Die Erfindung betrifft eine Sonotrode für eine Ultraschall-Schweißanlage nach dem Oberbegriff des Anspruchs 1.The invention relates to a sonotrode for an ultrasonic welding system the preamble of claim 1.

Schweißen ist eine Vereinigung von Werkstoffen unter Wärme und Druck.Welding is a combination of materials under heat and pressure.

Die Wärme wird hierbei folgendermaßen erzeugt:The heat is generated as follows:

Ein Generator liefert hochfrequente (z. B. 35 kHz) elektrische Energie, welche im Schallwandler (Konverter) mittels Piezoelementen in mechanische Längsschwin­ gungen umgewandelt werden.A generator supplies high-frequency (e.g. 35 kHz) electrical energy, which in the Sound converter (converter) by means of piezo elements in mechanical longitudinal vibration conditions are converted.

Diese hochfrequenten Schwingungen werden gegebenenfalls über einen Booster an eine Sonotrode übertragen und bewirken durch innere Reibung eine Aufhei­ zung des zu verschweißenden Kunststoffs. Die Sonotrode wird hierbei mit den zu verschweißenden Teilen in Verbindung gebracht.These high-frequency vibrations are possibly via a booster transferred to a sonotrode and cause heating due to internal friction the plastic to be welded. The sonotrode is used with the welding parts.

Der thermoplastische Kunststoff wird beim Anlegen der Sonotrode verflüssigt. Beim Abkühlen unter Druck entsteht eine Verbindung, welche Kräfte übertragen kann.The thermoplastic is liquefied when the sonotrode is put on. When cooling under pressure, a connection is created, which transmits forces can.

Je nach Kunststoff unterscheidet man z. B. zwischen "Fernfeldschweißen" (ge­ eignet nur für harte, spröde Kunststoffe mit geringem mechanischen Verlustfak­ tor), bei dem die hochfrequente Schwingung mit geringen Verlusten durch das Formteil hindurch zur Schweißstelle geleitet wird. Im Gegensatz dazu gibt es das "Nahfeldschweißen" oder "Kontaktschweißen", bei dem der Abstand zwischen Schalleinleitung und Schweißstelle gering ist, da die Schwingung im weichen Kunststoff schnell abgedämpft wird. Depending on the plastic, a distinction is made, for. B. between "far field welding" (ge only suitable for hard, brittle plastics with low mechanical loss factor gate), in which the high - frequency vibration with little loss through the Molding is passed through to the weld. In contrast, there is "Near field welding" or "contact welding", where the distance between Noise emission and welding point is low because the vibration in the soft Plastic is quickly dampened.  

Bei der flächigen Verschweißung mittels Ultraschall wird eine Wärmeenergie (z. B. 300 . . . 1200 Ws am Generator) pro Schweißstelle lokal in den Kunststoff eingebracht.In the case of surface welding using ultrasound, thermal energy is used (e.g. 300 ... 1200 Ws on the generator) per welding point locally in the plastic brought in.

Problematisch sind dabei Einfallstellen, welche sich auf der, der Verschweißung gegenüberliegenden Seite (z. B. lackierte Sichtfläche eines Stoßfängers für Kraftfahrzeuge) bilden.Sink marks, which are located on the weld, are problematic opposite side (e.g. painted visible surface of a bumper for Motor vehicles).

Beim Ultraschallschweißen z. B. von Schließteilen in die Stoßfänger-Außenhaut eines PKW wird heute üblicherweise mittels eines Schweißdomes (Rippe), auf den eine geschlitzte Lasche aufgeschoben wird, durch Nieten des Domes (pilz­ förmiger Wulst) eine kraftschlüssige Verbindung erzielt.When ultrasonic welding z. B. of locking parts in the bumper outer skin a car today is usually opened by means of a welding dome (rib) a slotted tab is pushed open by riveting the cathedral (mushroom shaped bead) achieved a positive connection.

Durch designbedingte Fugen, Kanten etc. war es bisher möglich, Rippen mit an die Außenhaut anzuspritzen, ohne dass die resultierenden Einfallstellen störend auffielen.Due to design-related joints, edges etc., it was previously possible to add ribs to spray the outer skin without disturbing the resulting sink marks stood out.

Wenn Rippen nicht möglich waren, wurde mit sog. "Flachsonotroden" "direkt", also flächig verschweißt.If ribs were not possible, so-called "flat sonotrodes" became "direct", welded flat.

Dabei ergeben sich störende Einfallstellen, welche vom Kunden normalerweise nicht akzeptiert werden.This creates annoying sink marks, which the customer normally does not be accepted.

Der Erfindung liegt die Aufgabe zu Grunde, eine Sonotrode für eine Ultraschall- Schweißanlage nach dem Oberbegriff des Anspruchs 1 so zu verbessern, dass störende Einfallstellen vermieden werden.The invention is based on the object of a sonotrode for an ultrasound Welding system according to the preamble of claim 1 to improve so that annoying sink marks can be avoided.

Erfindungsgemäß wird diese Aufgabe dadurch gelöst, dass auf der Kontaktfläche Zapfen angeordnet sind. Somit geschieht die Energieeinbringung nicht mehr über die Kontaktfläche, sondern über die Zapfen In bevorzugter Ausführungsform sind diese kegelförmig ausgebildet, wodurch ein leichteres Einstechen in den Werkstoff ermöglicht ist.According to the invention, this object is achieved in that on the contact surface Pins are arranged. This means that the energy input no longer occurs the contact surface, but over the pegs  In a preferred embodiment, these are conical, which means that easier insertion into the material is made possible.

Die Konizität der Zapfen liegt im Bereich 5° bis 20°, vorteilhafterweise ca. 10° zur Spitze hin.The taper of the pin is in the range 5 ° to 20 °, advantageously about 10 ° to Tip out.

Bevorzugt liegt die Länge der Zapfen geometrieabhängig bei zwei zu verschwei­ ßenden Bauteilen der Wandstärken von 2,7 und 3,6 mm zwischen 4 und 5 mm, vorzugsweise bei 4,3 mm.Depending on the geometry, the length of the pins is preferably two to be welded components with wall thicknesses of 2.7 and 3.6 mm between 4 and 5 mm, preferably at 4.3 mm.

In bevorzugter Ausführungsform sind auf der Kontaktfläche der Sonotrode zu­ mindest zwei parallele Reihen von Zapfen angeordnet. Alternativ sind drei paral­ lele Reihen von Zapfen vorgesehen, wobei die beiden äußeren Reihen acht Zapfen und die innerste Reihe aus neun Zapfen besteht. Grundsätzlich ist jede Ausführung einsetzbar, bei der die Zapfen in der Draufsicht symmetrisch zu zwei zueinander senkrechten Achsen angeordnet sind.In a preferred embodiment, the sonotrode is closed on the contact surface at least two parallel rows of pins arranged. Alternatively, three are parallel lele rows of pins provided, the two outer rows eight Cones and the innermost row consists of nine cones. Basically everyone is Version can be used in which the tenons are symmetrical in plan view mutually perpendicular axes are arranged.

Bevorzugt weist die Spitze der Zapfen einen in Längsrichtung symmetrischen dreieckigen Querschnitt auf mit einem Spitzenwinkel α von 60° < α < 150°, bevor­ zugt α = 120°.The tip of the pegs preferably has a symmetry in the longitudinal direction triangular cross section on with a tip angle α of 60 ° <α <150 ° before moves α = 120 °.

Vorteilhafterweise wird die Sonotrode zum Schweißen von thermoplastischen Kunststoffen verwendet, insbesondere zum Verschweißen von Außenteilen von Kraftfahrzeugen, wie Stoßfänger mit ihren Innenteilen, also Bauteile mit opti­ schen Anforderungen und dazugehörige Anbau- und Versteifungselemente.The sonotrode is advantageously used for welding thermoplastic materials Plastics used, especially for welding outer parts of Motor vehicles, such as bumpers with their inner parts, that is, components with opti requirements and associated attachment and stiffening elements.

Besonders vorteilhaft erweist es sich im Hinblick auf die Problematik der Einfall­ stellen, wenn die Teile vor dem Schweißen lackiert werden.It proves to be particularly advantageous with regard to the problem of the idea if the parts are painted before welding.

Aus Versuchen mit verschiedenen Sonotrodenformen hat sich ergeben, dass ei­ ne bestimmte Sonotrodenform, sog. "Fakirsonotrode" vorteilhafte Eigenschaften in Bezug auf die oben genannte Einfallstellenproblematik bietet. Versuche mit dieser Form ergaben durchweg die besten optischen Ergebnisse.Experiments with different sonotrode shapes have shown that ei ne certain sonotrode shape, so-called "Fakirsonotrode" advantageous properties  in relation to the sink marks problem mentioned above. Try with this form consistently gave the best optical results.

Die erfindungsgemäße Geometrie der Sonotrode besteht aus einer Vielzahl von kleinen Zapfen, welche eine Konizität (hier: ca. 10°) aufweisen (leichtes Entfor­ men beim Herausfahren der Sonotrode), sowie eine Spitze (begünstigt das An­ schmelzen). Durch die vielen kleinen Spitzen wird die benötigte Wärmeenergie besonders schonend bzw. gut verteilt in den Kunststoff eingebracht, was in ge­ ringen Einfallstellen resultiert. Die Länge der Zapfen wurde für die zu verschwei­ ßenden Wandstärken (2,7 mm auf 3,6 mm) in einem Versuch ermittelt. Günstig war hierbei die Zapfenlänge 4,3 mm.The geometry of the sonotrode according to the invention consists of a large number of small cones, which have a taper (here: approx. 10 °) (easy removal when the sonotrode is removed), as well as a tip (favors the approach melt). Due to the many small peaks, the required thermal energy introduced particularly gently or well distributed in the plastic, which in ge wrinkle sink marks results. The length of the spigot was too welded for that ß wall thicknesses (2.7 mm to 3.6 mm) determined in a test. Cheap the pin length was 4.3 mm.

Nachfolgend einige Beispiele mit einer erfindungsgemäßen Sonotrode.Below are some examples with a sonotrode according to the invention.

Einfluss der Reihenfolge von Schweißen und Lackieren:
Beim Schweißen von unlackierten Teilen der Wandstärken (2,7/3,0 mm) wurden Abzugskräfte von (270 ±30) N erreicht. Die anschließend lackierte Oberfläche zeigte schwache Einfallstellen.Influence of the order of welding and painting:
When welding unpainted parts with wall thicknesses (2.7 / 3.0 mm), pull-off forces of (270 ± 30) N were achieved. The subsequently painted surface showed weak sink marks.

Diese Einfallstellen konnten deutlich minimiert werden, wenn (bei ansonsten glei­ chen Bedingungen) eine lackierte Probeplatte verschweißt wurde. Allerdings sollte die zu verschweißende Seite frei von Lackspuren sein, um die Verschwei­ ßung nicht zu beeinträchtigen. Um die lackierte Oberfläche nicht zu beschädigen, sollte die Vorrichtung entsprechend ausgepolstert sein.These sink marks could be significantly minimized if (with otherwise the same conditions) a painted test panel was welded. Indeed the side to be welded should be free of traces of paint to prevent the weld not affect the food. In order not to damage the painted surface, the device should be padded accordingly.

Es ist festzustellen, dass ein vorheriges Lackieren sich positiv auf die optische Qualität der Sichtfläche im Hinblick auf Einfallstellen auswirkt. Die Erklärung hierfür dürfte in der Wärmeeinwirkung beim Lackieren liegen. It should be noted that previous painting has a positive effect on the optical Quality of the visible surface with regard to sink marks. The explanation this may be due to the effects of heat when painting.  

Diese Erklärung konnte in einem Versuch, bei dem ein vorher getempertes Teil verschweißt wurde und mit einem ungetempert verschweißtem Teil verglichen wurde, bestätigt werden: Der Einfall beim getemperten Teil ist geringer als beim ungetemperten, allerdings nicht unbedingt in dem Maße, wie beim lackierten Teil. Vermutlich hat die Lackschicht ebenfalls eine positive Wirkung bei der Reduzie­ rung der Einfallstellen.This explanation could be found in an experiment involving a previously annealed part was welded and compared with a non-annealed welded part was confirmed: The incidence of the annealed part is less than that of the untempered, but not necessarily to the extent that of the painted part. Presumably, the paint layer also has a positive effect on the reduction the sink marks.

Einfluss der Wandstärke:
Eine Erhöhung der Wandstärke der Stoßfänger von 3,0 mm auf 3,6 mm verrin­ gerte die Einfallstellen deutlich:
Für einen Schweißversuch mit einer Fakirsonotrode, Wandstärken von (2,7/3,6 mm) und dem Verschweißen der unlackierten Teile konnten Abzugskräfte von (300 ±40) N gemessen werden. Die anschließend lackierten Probeplatten zeigten nahezu keine Einfallstellen mehr.Influence of wall thickness:
Increasing the wall thickness of the bumpers from 3.0 mm to 3.6 mm significantly reduced the sink marks:
For a welding test with a fakirsonotrode, wall thicknesses of (2.7 / 3.6 mm) and the welding of the unpainted parts, pull-off forces of (300 ± 40) N could be measured. The subsequently coated test panels showed almost no sink marks.

Einfluss der Zapfenlänge/Eintauchtiefe:
Ausgehend von der ursprünglichen Fakirsonotrode (Zapfenlänge 3 mm) wurde eine Fakirsonotrode mit kürzeren Zapfen (Zapfenlänge 3,4 mm) angefertigt, um zu untersuchen, ob auf diese Weise eine Verminderung der Einfallstellen zu er­ reichen ist.Influence of the tenon length / immersion depth:
Starting from the original fakirsonotrode (pin length 3 mm), a fakirsonotrode with shorter pins (pin length 3.4 mm) was made to investigate whether it was possible to reduce the sink marks in this way.

Dabei stellte sich heraus, dass mit dieser kurzen Zapfenlänge eine zuverlässige Verschweißung (Wandstärken (2,7/3,0, Abzugskraft <200 N) nur zu erreichen ist, wenn die Sonotrode komplett abgesenkt wird, d. h. die gesamte Sonotrode zeichnet sich im Bauteil ab. Hierbei wird sehr viel Energie (<700 Ws) in den Kunststoff eingebracht; die Einfallstellen sind stark ausgeprägt. Günstiger sind also lange Zapfen, da hierbei der Sonotrodengrund die zu verschweißenden Platten nicht berührt; es zeichnen sich nur die Zapfen ab. Nur etwa halb soviel Energie (um 300 Ws) wird bei ansonsten gleichen Bedingungen benötigt, um die Bauteile zu verschweißen und die Einfallstellen sind weniger ausgeprägt.It turned out that with this short tenon length a reliable Welding (wall thicknesses (2.7 / 3.0, pull-off force <200 N) can only be achieved, when the sonotrode is completely lowered, d. H. the entire sonotrode emerges in the component. Here a lot of energy (<700 Ws) in the Plastic introduced; the sink marks are pronounced. Are cheaper So long cones, since the bottom of the sonotrode is the one to be welded Plates not touched; only the cones are visible. Only about half as much  Energy (around 300 Ws) is required to achieve the same conditions Welding components and the sink marks are less pronounced.

Für eine ausreichende Verschweißung (Abzugskraft <200 N) ist es also nicht er­ forderlich, die Sonotrode bis zum Zapfengrund abzusenken. Der Anpressdruck kann allein über die Niederhalter aufgebracht werden. Dies wird bei der sog. "Tiefenabschaltung" ausgenutzt, hierbei wird der Ultraschall abgeschaltet, sobald die Sonotrode eine definierte Tiefe erreicht hat.For a sufficient weld (pull-off force <200 N) it is therefore not him required to lower the sonotrode to the base of the cone. The contact pressure can be applied using the hold-down device alone. This is the so-called "Deep shutdown" exploited, the ultrasound is switched off as soon as the sonotrode has reached a defined depth.

Weitere Merkmale ergeben sich aus den Figuren, die nachfolgend beschreiben sind. Es zeigt:Further features result from the figures, which describe below are. It shows:

Fig. 1 eine erfindungsgemäße Sonotrode, Fig. 1 is a sonotrode according to the invention,

Fig. 2 einen einzelnen Zapfen der Sonotrode und Fig. 2 shows a single pin of the sonotrode and

Fig. 3 eine Ansicht der Kontaktfläche der Sonotrode. Fig. 3 is a view of the contact surface of the sonotrode.

Fig. 1 zeigt eine erfindungsgemäße Sonotrode 2, auch Fakirsonotrode genannt. Diese Sonotrode ist - nicht gezeigt - über gegebenenfalls einem Booster mit dem Schallwandler (Konverter) einer Ultraschall-Schweißanlage verbunden. Fig. 1 shows a sonotrode 2 according to the invention, also called fakir. This sonotrode is - not shown - connected to the sound transducer (converter) of an ultrasound welding system, possibly via a booster.

Die Kontaktfläche 3 der Sonotrode 2 weist drei Reihen von Zapfen 1 auf, wobei die innerste Reihe neun Zapfen 1 aufweist und die beiden äußersten Reihen je­ weils acht Zapfen 1.The contact surface 3 of the sonotrode 2 has three rows of pins 1 , the innermost row having nine pins 1 and the two outermost rows each having eight pins 1 .

Fig. 3 zeigt eine Draufsicht auf die Kontaktfläche 3 mit den einzelnen Zapfen 1 der Sonotrode 2. Fig. 3 shows a plan view of the contact surface 3 with the individual pin 1 of the sonotrode. 2

Fig. 2 zeigt einen einzelnen Zapfen. Die Zapfenlänge ist mit h bezeichnet. Der Zapfen 1 ist kegelförmig ausgebildet, wobei sich der Zapfen 1 zur Spitze hin um ca. 10° verjüngt. Die Spitze 4 des Zapfens 1 weist einen pyramidenförmigen Querschnitt auf mit einem Spitzenwinkel α von 120°. Der an der Kontaktfläche 2 sich befindliche Fuß des Zapfens 1 hat einen Durchmesser von d2 = 2,0 mm, und der Durchmesser an der Spitze 4 beträgt d1 = 1,4 mm. Fig. 2 shows a single pin. The tenon length is designated with h. The pin 1 is conical, the pin 1 tapering towards the tip by approximately 10 °. The tip 4 of the pin 1 has a pyramid-shaped cross section with a tip angle α of 120 °. The foot of the pin 1 located on the contact surface 2 has a diameter of d 2 = 2.0 mm, and the diameter at the tip 4 is d 1 = 1.4 mm.

Claims (8)

1. Sonotrode für eine Ultraschall-Schweißanlage mit einem Ultraschall- Generator, der hochfrequente elektrische Energie an einen Konverter feitet, dieser die Energie in mechanische Schwingungen umwandelt und gegebe­ nenfalls über einen Booster an eine Sonotrode (2) leitet, wobei die Sonotro­ de (2) mit einer Kontaktfläche (3) ausgebildet ist, dadurch gekennzeichnet, dass auf der Kontaktfläche (3) Zapfen (1) angeordnet sind.1. Sonotrode for an ultrasound welding system with an ultrasound generator that feeds high-frequency electrical energy to a converter, which converts the energy into mechanical vibrations and, if necessary, conducts it via a booster to a sonotrode ( 2 ), the Sonotro de ( 2 ) is formed with a contact surface ( 3 ), characterized in that pins ( 1 ) are arranged on the contact surface ( 3 ). 2. Sonotrode nach Anspruch 1, dadurch gekennzeichnet, dass die Zapfen (1) kegelförmig ausgebildet sind.2. Sonotrode according to claim 1, characterized in that the pins ( 1 ) are conical. 3. Sonotrode nach Anspruch 2, dadurch gekennzeichnet, dass die Konizität der Zapfen (1) zwischen 5° und 20°, bevorzugt ca. 10° zur Spitze hin be­ trägt.3. Sonotrode according to claim 2, characterized in that the conicity of the pin ( 1 ) between 5 ° and 20 °, preferably about 10 ° towards the tip. 4. Sonotrode nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, dass die Länge (h) der Zapfen (1) geometrieabhängig bei zwei zu ver­ schweißenden Bauteilen der Wandstärken 2, 7 und 3,6 mm zwischen 4 und 5 mm, vorzugsweise 4,3 mm beträgt.4. Sonotrode according to one of claims 1 to 3, characterized in that the length (h) of the pin ( 1 ) geometry-dependent in two to be welded components of the wall thicknesses 2, 7 and 3.6 mm between 4 and 5 mm, preferably 4th , 3 mm. 5. Sonotrode nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, dass die Zapfen in der Draufsicht achsensymmetrisch zu zwei zueinander senkrechten Achsen angeordnet sind, z. B. in 3 parallelen Reihen mit außen acht Zapfen und neuen Zapfen in der Mitte.5. Sonotrode according to one of claims 1 to 4, characterized in that the pegs are axially symmetrical to each other in plan view vertical axes are arranged, for. B. in 3 parallel rows with the outside eight cones and new cones in the middle. 6. Sonotrode nach einem der Ansprüche 1 bis 5, dadurch gekennzeichnet, dass die Spitze (4) der Zapfen (1) einen in Längsrichtung symmetrischen dreieckigen Querschnitt aufweist, mit einem Spitzenwinkel α von 60° < α < 150°, bevorzugt α = 120°. 6. Sonotrode according to one of claims 1 to 5, characterized in that the tip ( 4 ) of the pin ( 1 ) has a triangular cross section symmetrical in the longitudinal direction, with a tip angle α of 60 ° <α <150 °, preferably α = 120 °. 7. Sonotrode nach einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, dass die Sonotrode (2) zum Schweißen von thermoplastischen Kunststoffen verwendet wird, insbesondere zum Verschweißen von Außenteilen von Kraftfahrzeugen, wie Stoßfänger mit ihren Innenteilen, also Bauteile mit op­ tischen Anforderungen und dazugehörige Anbau- und Versteifungselemen­ te.7. Sonotrode according to one of claims 1 to 6, characterized in that the sonotrode ( 2 ) is used for welding thermoplastic materials, in particular for welding outer parts of motor vehicles, such as bumpers with their inner parts, that is to say components with operational requirements and associated ones Attachment and stiffening elements. 8. Verfahren zum Schweißen von Kunststoffteilen mit einer Sonotrode (2) nach einem der Ansprüche 1 bis 7, dadurch gekennzeichnet, dass die Teile vor dem Schweißen lackiert werden.8. A method for welding plastic parts with a sonotrode ( 2 ) according to any one of claims 1 to 7, characterized in that the parts are painted before welding.
DE10160496A 2001-04-21 2001-12-08 Sonotrode for an ultrasonic welding system Ceased DE10160496A1 (en)

Priority Applications (7)

Application Number Priority Date Filing Date Title
DE10160496A DE10160496A1 (en) 2001-04-21 2001-12-08 Sonotrode for an ultrasonic welding system
PT02007443T PT1250996E (en) 2001-04-21 2002-03-30 ULTRASOUND WELDING SYSTEM AND PROCESS FOR POINTS
AT02007443T ATE328721T1 (en) 2001-04-21 2002-03-30 SONOTRODE FOR AN ULTRASONIC WELDING SYSTEM
DE50207058T DE50207058D1 (en) 2001-04-21 2002-03-30 Sonotrode for an ultrasonic welding system
EP02007443A EP1250996B1 (en) 2001-04-21 2002-03-30 Sonotrode for an ultrasonic welding apparatus
ES02007443T ES2266335T3 (en) 2001-04-21 2002-03-30 SONOTRODE FOR AN ULTRASOUND WELDING INSTALLATION.
US10/126,524 US6776323B2 (en) 2001-04-21 2002-04-22 Sonotrode for ultrasound welding of plastics

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE10119614 2001-04-21
DE10160496A DE10160496A1 (en) 2001-04-21 2001-12-08 Sonotrode for an ultrasonic welding system

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7344620B2 (en) 2004-05-10 2008-03-18 Bandelin Electronic Gmbh & Co. Kg Ultrasonic sonotrode
DE102013223166A1 (en) * 2013-11-14 2015-05-21 Bayerische Motoren Werke Aktiengesellschaft Sonotrode for ultrasonic welding, ultrasonic welding machine, ultrasonic welding process and welded joint
EP3838566A1 (en) 2019-12-16 2021-06-23 Henkel AG & Co. KGaA Method for welding plastics with reduced impression effect
EP3848185A1 (en) * 2020-01-09 2021-07-14 Magna Exteriors (Bohemia) s.r.o. Method for ultrasonically welding two plastic components and plastic components produced thereby

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7344620B2 (en) 2004-05-10 2008-03-18 Bandelin Electronic Gmbh & Co. Kg Ultrasonic sonotrode
DE102013223166A1 (en) * 2013-11-14 2015-05-21 Bayerische Motoren Werke Aktiengesellschaft Sonotrode for ultrasonic welding, ultrasonic welding machine, ultrasonic welding process and welded joint
EP3838566A1 (en) 2019-12-16 2021-06-23 Henkel AG & Co. KGaA Method for welding plastics with reduced impression effect
EP3848185A1 (en) * 2020-01-09 2021-07-14 Magna Exteriors (Bohemia) s.r.o. Method for ultrasonically welding two plastic components and plastic components produced thereby
US11628629B2 (en) 2020-01-09 2023-04-18 Magna Exteriors (Bohemia) s.r.o. Method for the ultrasonic welding of two plastic components, and plastic component produced thereby

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