TWI419785B - 熔接功能性組件至聚合物複合組件 - Google Patents

熔接功能性組件至聚合物複合組件 Download PDF

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Publication number
TWI419785B
TWI419785B TW96110794A TW96110794A TWI419785B TW I419785 B TWI419785 B TW I419785B TW 96110794 A TW96110794 A TW 96110794A TW 96110794 A TW96110794 A TW 96110794A TW I419785 B TWI419785 B TW I419785B
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Taiwan
Prior art keywords
thermoplastic
polymer
component
thermoset
functional component
Prior art date
Application number
TW96110794A
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English (en)
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TW200806459A (en
Inventor
Andrew Beehag
Adrian Jackson
Meng Hou
Rowan Johnson Paton
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Crc For Advanced Composite Structures Ltd
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Priority claimed from AU2006901580A external-priority patent/AU2006901580A0/en
Application filed by Crc For Advanced Composite Structures Ltd filed Critical Crc For Advanced Composite Structures Ltd
Publication of TW200806459A publication Critical patent/TW200806459A/zh
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • 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
    • B29C66/302—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
    • B29C66/30221—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 point-like
    • 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
    • B29C65/04—Dielectric heating, e.g. high-frequency welding, i.e. radio frequency welding of plastic materials having dielectric properties, e.g. PVC
    • 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
    • B29C65/02—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
    • B29C65/0609—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 characterised by the movement of the parts to be joined
    • B29C65/0627—Angular, i.e. torsional
    • 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
    • B29C65/10—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using hot gases (e.g. combustion gases) or flames coming in contact with at least one of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
    • B29C66/474—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially non-flat
    • 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
    • B29C66/71—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 composition of the plastics material of the parts to be joined
    • B29C66/712—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 composition of the plastics material of the parts to be joined the composition of one of the parts to be joined being different from the composition 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
    • B29C66/72—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
    • 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
    • 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
    • B29C66/735—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 extensive physical properties of the parts to be joined
    • B29C66/7352—Thickness, e.g. very thin
    • 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
    • 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
    • B29C66/7375—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 uncured, partially cured or fully cured
    • B29C66/73751—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 uncured, partially cured or fully cured the to-be-joined area of at least one of the parts to be joined being uncured, i.e. non cross-linked, non vulcanized
    • 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
    • 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
    • B29C66/70—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
    • B29C66/7394—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 thermoset
    • 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
    • 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
    • B29C66/81431—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 comprising a single cavity, e.g. a groove
    • 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
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Description

熔接功能性組件至聚合物複合組件 發明領域
本發明是關於熱塑性聚合物和熱固性聚合物複合物組件的結合。特別地，本發明是關於透過高頻振動的應用，使含有熱塑性聚合物的一組件熔接至具有一熱塑性表面的聚合物複合物組件。
 發明背景
纖維加強聚合物組件，在其他方面被瞭解為聚合物複合物組件，是由與一聚合物樹脂(常常被瞭解為是基質)一同被支撐的加強纖維構成。這種基質可以是一熱塑性聚合物，諸如一環氧樹脂，在這種情況下該複合物組件可被稱為一熱固性複合物組件，或者一熱塑性聚合物，也被瞭解為一熱塑性塑膠，諸如聚醯胺或聚醚醚酮，在這種情況下該組件可被稱為一熱塑性複合物組件。應注意的是一熱固性複合物組件可含有少量的熱塑性聚合物，例如像一表面膜、一樹脂添加劑或一黏合劑。一熱塑性複合物組件可以相同的方式含有少量的熱固性聚合物，例如像一核心或插入物。
大部分結構聚合物複合物具有一熱固性基質。因此用於使其他組件結合到這些結構聚合物組件的技術是基於可用於熱固性複合物、機械固定和黏接的結合該等標準方法。這些結合方法是緩慢的方法，並且因此增加了相當大的裝配的費用，甚至對於少量組件的連接。
小功能組件，也被瞭解為附件或配件並且包括支座、螺椿、襯套和托架和類似的物件，被用來使各種物品連接到結構熱固性複合物積層物和結構。這些功能性組件傳統上是金屬的，但是也可是由熱塑性塑膠、加強熱塑性塑膠、不同種類的加強纖維複合物和其他材料或此等之組合製造。如果在固化之前該功能型組件被埋入該複合物材料中，一高強度的附件可在這樣一功能性組件和一複合物材料之間得到。可是這總是不可能的並且常常是不方便的。附件因此是經由機械結件或黏合物的使用被完成而結合到該功能性組件。這些方法是也通常被用於使功能性組件結合到由金屬和其他材料製造的結構的方法。機械結件為該複合物積層物提供高強度的附件；可是該附件要求在該複合物積層物內鑽孔，導致在該複合物積層物內機械性質潛在的降低。在很多方案中，非常較佳的是透過黏接來連接該功能性組件。可是在黏合劑被使用中，該等功能性組件可能具有比黏接更大的承載能力。當該複合物組件被塗漆時，對於強的黏接一額外的障壁會發生。在這種情況下，一黏接的強度常常是由在該油漆和組件之間的低的黏附力位準控制的。常常，為了得到可靠的附件，這要求除去在連接該功能性組件附近內的油漆。
便宜的並且容易被大量生產的功能性組件可由熱塑性塑膠或加強熱塑膠部分地或全部地製造。可是，它們還未容易地被採用，部分是因為要得到具有好的黏接力的這些組件是困難的。為了在一熱塑性功能性組件和一熱固性複合物之間製造一高強度的黏接，無論是該熱固性複合物的表面還是該熱塑性功能性組件的表面通常都要求表面處理。在熱固性複合物的情況下，該表面處理可是該表面的摩擦並且用一適當的溶劑清洗。在熱塑性塑膠的情況下，該表面處理可是諸如電暈放電或氣體電漿處理的多種處理之一。
因此對於本發明所希望的是透過提供用於使一部分地或完全地由熱塑性塑膠製造的功能性組件連接到一熱固性複合物積層物或組件的方法，來緩和(至少是某種程度上)該等上面問題的一個或多個。有利地，該方法可被用於使一功能性組件連接到具有非常高的附件強度的該熱固性複合物組件上。更有利地，該方法非常迅速，並且能允許在該功能性組件至熱固性複合物表面的附件的成本的很大的降低。該方法既可被應用到被塗漆的複合物組件也可被應用到未被塗漆的複合物組件上。
 發明概要
概括地，本發明包括用於使一包含至少部分地熱塑性聚合物的功能性組件結合至一熱固性聚合物複合物組件的一種方法，該熱固性聚合物複合物組件即大體上是由熱固性聚合物和增強纖維製造的一組件。
本發明的一第一具體例提供使一功能性組件結合至一熱固性聚合物複合物組件的一種方法，該熱固性複合物組件包含一熱固性聚合物複合物材料，以及在至少部分要被結合的表面上的一熱塑性聚合物層，該方法包括該等如下步驟：選擇一功能性組件，該功能性組件具有至少在要被結合的表面上的一第二熱塑性聚合物，該第二熱塑性聚合物是被選擇以使得它在高頻振盪相對位移或高速連續相對位移熔接操作中可與該熱固性聚合物複合物組件的熱塑性表面形成高強度接頭；使該複合物組件的該熱塑性表面位於與該功能性組件的熱塑性表面緊密接觸的位置；在該熱固性聚合物複合物組件和該功能性組件之間施加一高頻振盪相對位移或高速連續相對位移，藉此該等組件的該等各自的熱塑性表面的至少一部分是至少部分地熔化和熔融；停止該高頻振盪相對位移或高速連續相對位移，並且使該熱固性聚合物複合物組件和該功能性組件以一固定的關係保持在一起，藉此該熔化的熱塑性塑膠或該等熔化的熱塑性塑膠再凝固並且該等組件被熔接在一起。
較佳地，根據本發明的該第一具體例，在至少該功能性組件或熱固性聚合物複合物組件上的該熱塑性表面會被形成一個或多個突出，或一表面紋理，或導能器，藉此在高頻振盪相對位移或高速連續相對位移熔接中消失的能量引發這些突出熔化。在該功能性組件上的該等突出可被製成小於或等於在該熱固性組件上的熱塑性塑膠的厚度的尺 寸。有利地，這樣有助於提供在功能性組件和熱固性複合物組件之間的一無縫結合。
較佳地，根據本發明的該第一具體例，透過該等如下步驟，在該熱固性聚合物複合物組件上形成該熱塑性表面：選擇未固化的熱固性聚合物複合物樹脂構件和一第一熱塑性聚合物，它們具有表示該熱塑性聚合物和未固化熱固性聚合物樹脂構件相互滲透能力的Hansen溶解度參數；使該熱塑性聚合物位於與該未固化的熱固性聚合物複合物組件接觸的位置，藉此當被固化時至少一部分的該複合物組件的一表面是由該熱塑性聚合物構成；使該熱塑性聚合物和未固化熱固性聚合物複合物組件加熱至該熱固性聚合物的固化溫度，在該熱固性聚合物固化之前，該等未固化的熱固性聚合物樹脂構件和該熱塑性聚合物能至少部分地相互滲透；以及使該熱塑性聚合物和固化的熱固性聚合物組件冷卻，藉此該熱塑性聚合物能強烈地連接到該固化的熱固性聚合物組件。
有利地，在該組件固化的時候透過使一熱塑性表面結合到該熱固性聚合物複合物組件之上，該熱塑性聚合物表面層以一高強度位準連接到該熱固性聚合物複合物。
本發明的一第二具體例提供使一功能性組件結合至一經塗覆的熱固性聚合物複合物組件的一種方法，該熱固性聚合物複合物組件包含一熱固性聚合物複合物材料，與在 要被結合的表面的至少該部分上的一熱塑性聚合物層和一覆蓋該熱塑性聚合物層的聚合性塗層，該方法包括該等如下步驟：選擇一功能性組件，該功能性組件具有至少在要被結合的表面上的一第二熱塑性聚合物，該第二熱塑性聚合物是這樣被選擇的，以使得它在高頻振盪相對位移或高速連續相對位移熔接操作中與在該熱固性聚合物複合物組件的聚合性塗層之下的熱塑性表面形成高強度接頭；使該複合物組件的該熱塑性表面位於與該功能性組件的該經塗覆的熱塑性表面緊密接觸的位置；在該熱固性聚合物複合物組件和該功能性組件之間施加一高頻振盪相對位移或高速連續相對位移，藉此在該熱塑性表面之上的該聚合性材料塗層的至少一部分被移開並且該等組件的該等各自的熱塑性表面的至少一部分接觸、熔化和熔融；以及停止該高頻振盪相對位移或高速連續相對位移，並且使該熱固性聚合物複合物組件和該功能性組件以一固定的關係保持在一起，藉此該熔化的熱塑性塑膠或該等熔化的熱塑性塑膠再凝固並且該等組件被結合在一起。
較佳地，根據本發明的該第二具體例，在該功能性組件上的該熱塑性表面會被形成一個或多個突出，或一表面紋理，或導能器，藉此在高頻振盪相對位移或高速連續相對位移熔接中消失的能量引發這些突出熔化。在該功能性組件上的該等突出可被製成大於該覆蓋該熱固性複合物組 件表面上的熱塑性層的聚合性材料的厚度的尺寸。有利地，在該功能性組件的該等熱塑性突出和該熱固性複合物組件的熱塑性表面開始接觸並且至少部分地熔化和熔融之前，這有助於移開該聚合性塗層。
較佳的是根據本發明的第二具體例，該經塗覆的熱固性聚合物複合物是透過該等如下步驟形成的：選擇未固化的熱固性聚合物複合物樹脂構件和一第一熱塑性聚合物，它們具有表示該熱塑性聚合物和未固化熱固性聚合物樹脂構件相互滲透能力的Hansen溶解度參數；使該熱塑性聚合物位在與該未固化的熱固性聚合物複合物組件接觸的位置，以使得當固化時該熱塑性聚合物構成該複合物組件的一表面的至少一部份；使該熱塑性聚合物和未固化熱固性聚合物複合物組件加熱至該熱固性聚合物的固化溫度，在該熱固性聚合物固化之前，該等未固化的熱固性聚合物樹脂構件和該熱塑性聚合物能至少部分地相互滲透；使該熱塑性聚合物和固化的熱固性聚合物組件冷卻，藉此該熱塑性聚合物能強烈地連接到該固化的熱固性聚合物組件；以及用一聚合性材料層塗覆該熱固性聚合物組件，該熱固性聚合物組件包括該熱塑性表面。
有利地，在該組件固化的時候透過使一熱塑性表面結合到該熱固性聚合物複合物組件之上，該熱塑性聚合物表面層以一高強度位準連接到該熱固性聚合物複合物。
使用本發明的任一具體例的一額外的優點是：該功能性組件可被貼到該熱固性聚合物複合物組件的表面上，而不會危及該原始複合物組件的結構設計或性能，危及原始複合物組件的結構設計或性能可能發生在例如鑽孔，而影響機械固定。
較佳地對於任一具體例，該功能性組件是由純的熱塑性聚合物、一任何種類的共聚物或一任何種類的聚合物摻合物構成，或者在該熱塑性材料內包含一定百分比的填料、纖維或其他材料。其中在該功能性組件完全是由熱塑性塑膠或加強熱塑膠製造的情況下，它可簡單地透過諸如射出成形的一方法而被簡單地製造。可選擇地，該功能性組件可由與一金屬次組件組合的一經填充或未經填充的熱塑性塑膠構成。其中該組件是一熱塑性塑膠或加強熱塑膠和金屬之組合，該金屬部分可透過加工、鑄造、澆鑄或類似的方式被製造，並且該熱塑性塑膠或加強熱塑膠作為一配件被放置在該金屬之上。可選擇地，該金屬的部分可透過將該金屬組件放在一射出成形模內，而與熱塑性塑膠或加強熱塑膠被”覆蓋射出”。
該功能性組件也可是一較大的組件，它以一系列局部”點”熔接或在一連續”接縫”熔接操作中被熔接至該熱固性聚合物複合物組件，其中一長的功能性組件和一熱固性聚合物複合物組件是被橫向移動穿過該熔接器並且該接頭是透過該熔接器被連續製造的。
有利地，其中一最小的熔接品質是經由熔接而達到的，連接到該熱固性聚合物複合物組件的該功能性組件的強度不是取決於連接到該熱固性聚合物複合物組件的熱塑性塑膠的強度，就是取決於連接到該功能性組件的熱塑性塑膠的強度。在該熱固性聚合物複合物組件的情況下，非常高的強度可透過利用本發明的方法經由在該未固化的熱固性聚合物和熱塑性聚合物之間的相互滲透而被達到。在該功能性組件的情況下，這取決於該組件的設計，但是對於一純的熱塑性塑膠組件，會是該基礎塑膠的強度。
大體上，一種用於在一熱固性複合物上提供一可熔接的表面的方法會要求該熱塑性層具有充足的厚度來允許高頻振盪相對位移或高速連續相對位移熔接發生。其中在用於一特殊操作的一熱固性複合物組件的表面上有一不充足的熱塑性塑膠，該方法在此操作之前或之中也可包括額外的熱塑性聚合物、與其他材料組合的純的聚合物或聚合的加入。
有利地，透過本發明的方法在一熱固性聚合物複合物組件上一熱塑性表面被創建，它可透過本發明的方式被馬上或在一較晚的日期用於一功能性組件的連接。此外，在一功能性組件需要被代替的情況下，該功能性組件可透過切割、研磨或一類似的方法而被除去，只要熱塑性塑膠被保留在該熱固性聚合物組件的表面上。可選擇地，該功能性組件可透過來自某些來源的熱的應用被”去熔接”或是被除去。該所產生的表面可能需要被適當地處理，大體上是透過弄平或清潔，或者透過額外的熱塑性材料的加入或熔接，此後另一功能性組件可被適當熔接，可達到高的接頭強度。
一個或多個功能性組件可在該複合物上的每一個連續的熱塑性表面處被熔接至該熱固性聚合物複合物組件。此外，多個熱塑性表面的區域出現在該熱固性聚合物複合物組件的表面上，功能性組件可被結合到部分或全部的那些區域上。
根據本發明的另一方面，提供用於使一功能性組件熔接到一熱固性聚合物複合物組件上的一種儀器，該儀器包含用於在該功能性組件和該熱固性聚合物複合物組件之間施加一高速連續相對位移或高頻振盪相對位移的一引動器、用於使該引動器的相對位移施加到該功能性組件的一工具，以及用於定位該引動器相對於該功能性組件的位置及/或向該功能性組件施加壓力的至少一結構。
本發明這個方面的該熔接儀器可在該功能性組件和熱固性聚合物複合物組件之間施加高速連續相對位移或高頻振盪相對位移。它使在本發明的第一和第二具體例中的該等組件之一開始接觸。該熔接儀器可是一可攜帶的超音波熔接單元，具有一手持部分，它通常在20kHz的頻率下運行。可選擇地，該熔接儀器可是一旋轉式熔接機，它可在該功能性組件和該熱固性聚合物複合物組件之間施加一高速旋轉相對運動。
向該功能性組件施加相對位移的該熔接工具選擇性地具有一成形的介面，該介面穩固地位於該功能性組件之上或者支撐該功能性組件。該工具可是固體或者具有一空的中心來允許不同形狀的功能性組件被熔接。
該熔接儀器還具有用於定位該引動器相對於該功能性組件的位置及/或向該功能性組件施加壓力的一個或多個結構。以一不中斷施加相對位移至要被熔接的該等組件的的方式，在熔接時該定位及/或壓力結構被穩固地連接到該熔接儀器。這些結構能抑制該熔接儀器的橫向移動，並且還增加在該等被熔接的組件上的該熔接工具的壓力。在該等結構具有相對於高頻熔接儀器被移動或被調節的能力的情況下，在熔接操作之前該等結構可被穩固地固定在該熔接儀器，並且隨後被釋放。此外該等結構可允許一光延伸力被連續地施加或被週期性地被施加，在熔接操作之前允許該等結構延伸到該熔接工具的末端之外而得到該熔接工具的最佳排列。該等結構可包括被部分地或全部地排空的一遮板和一室，藉此一淨力是被施加到該熔接工具的末端。該遮板或室可包括在一末端的密封組件，使得能製造出與該功能性組件或該熱固性複合物組件的一氣密密封。
在本發明中，該術語”熱塑性聚合物”可以是指一純的熱塑性聚合物、任何種類的一共聚物或任何種類的一聚合物摻合物。該熱塑性聚合物還可包含在該熱塑性材料中的若干百分比的填料、纖維或其他材料。該熱塑性聚合物可被分成半晶性或非晶性。此外，在熔接中該等分開的熱塑性塑膠是相容的場合中，在該熱固性複合物組件上的該表面熱塑性塑膠可是與該功能性組件的熱塑性塑膠不同的一熱塑性塑膠。
本發明在另一方面提供一熱固性複合物組件，該熱固性複合物組件具有由上面方法描述而被連接的一功能性組件。
圖式簡單說明
第1圖說明一聚合物的Hansen溶解度圖，該圖可被用於測量一溶劑對於一特別的聚合物的溶解度；第2圖是在高壓釜固化之前熱固性聚合物複合物預浸體和熱塑性膜的一示意圖；第3A圖是一由熱塑性塑膠或加強熱塑膠製成的一普通的功能性組件或配件的示意圖；第3B圖是一由一具有熱塑性塑膠封閉的基底的金屬組件製成的一普通的功能性組件或配件的示意圖；第3C圖是一由被插入一熱塑性基底內的一金屬組件製成的一普通的功能性組件或配件的示意圖；第3D圖是第3C圖的一底面圖，顯示出一部分金屬基底和在該熱塑性基底中的金字塔形狀的導能器；第4圖是一功能性組件或類似於3B的配件、一具有一熱塑性表面的固化的熱固性複合物組件和一熔接儀器的較低部分的示意圖；第5圖是一功能性組件或類似於3B的配件、一具有一具有聚合性塗層的一熱塑性表面的固化的熱固性複合物組件和一熔接儀器的較低部分的示意圖；第6A圖是一功能性組件或類似於3B的配件、一具有一熱塑性表面的固化的熱固性複合物組件和一具有一環狀真空遮板的熔接儀器的較低部分的示意圖；及第6B圖是一功能性組件或配件、一具有一熱塑性表面的固化的熱固性複合物和一具有可調節真空管的熔接儀器的較低部分的示意圖。
 較佳實施例之詳細說明
會被理解的是在本說明書中被揭露和被定義的該發明擴展到提到的或明顯來自正文或圖的該等特徵的一個或兩個之全部可選擇的組合。所有這些不同的組合構成了本發明的各種可選擇的方面。
根據本發明的該第一或第二具體例，具有一熱塑性表面的熱固性複合物被要求連續地連接到一配件。下面的一簡明的討論是有關這樣的一表面經處理的複合物的成功形成、材料可相容性要求、材料選擇和成功的表面整合。
聚合物熱力學和溶解度準則
可相容的材料的選擇要求幾個溶解度參數的一準確匹配。對於一可相容的非晶性熱塑性塑膠的材料選擇的原理是基於混合的吉布士自由能(△Gm )，它規定△Gm ＝△Hm －T△Sm ≦0 (1)其中，△Hm 是混合焓，T是溫度以及△Sm 是混合熵。
Hidebrand－Scatchard方程式繼而被用來測量混合焓：△Hm ＝V Φa Φb (δa －δb )2 (2)其中δa 和δb 是例如非晶性聚合物和單體或硬化劑的兩種要考量的物質的該等溶解度參數(也是已知的Hidebrand參數)。
可是，Hidebrand－Scatchard方程式(上面的方程式(2))的使用對於可應用於本發明的高性能半晶性熱塑性塑膠的類型是不充分的，因為諸如極性力的分子間力能很大程度上影響這些聚合物的溶解度行為。考慮到分散度、極性和氫鍵力的Hansen參數的使用被介紹為一合適的方法，該方法能同時地應用到非晶性和半晶性聚合物(見AFM Barton“CRC Handbook of Solubility Parameters and otherCohesion parameter”,CRC Press,Boca raton,1983)。這些參數的應用提供對於聚合物溶劑相容性的合理的指導。對於聚合物b相容性的半徑被定義為半徑b R，如在第1圖中的溶解度圖中顯示的。對於任何溶劑a的有關分散度(δd )、極性(δp )和氫鍵力(δh )的該等Hansen溶解度參數可在該圖上被計算以及被繪製。在該溶解度圖上定出溶劑a的三個Hansen參數的點的位置是位於由b R定義的該球體內的情況下，該聚合物是可溶在該溶劑中的，也就是[4(a δd －b δd )2 ＋(a δp －b δp )2 ＋(a δh －b δh )2 ]1/2 <b R (3)其中在這種情況中該溶劑是單體或硬化劑，以及b R是使用具有已知Hansen參數的普通溶劑透過標準實驗而被測量的。
材料的選擇和表面的整合
根據上面的準則選擇的一熱塑性材料可被成功地整合，是透過在一熱固性聚合物或熱固性聚合物材料的表面上一實質的半相互滲透聚合物網路(SIPN)的形成而被整合的。此方法的一方面是一熱固性聚合物和一具有一透過使用Hansen參數測量的溶解度的熱塑性塑膠的選擇，以及一固化溫度/時間迴圈的選擇，該熱固性單體和硬化劑能充分地遷移到該非晶性聚合物內或透過克服該晶性組件的熔化熱充分地遷移到該半晶性熱塑性塑膠的該晶性組件內。在該組件的固化之後，經由分子鏈的纏結，在該等初始的表面的區域內該熱塑性塑膠被緊密地連接到該組件，因此在該熱固性樹脂和該熱塑性樹脂之間形成一半相互滲透的聚合物網路。
有利地，當符合上面的熱力學和溶解度相容性準則時，在無需改變製造商推薦的對於該熱固性聚合物的固化迴圈下，該連接方法可典型地發生。
本發明的較佳具體例
在本發明的該等較佳具體例中，一第一熱塑性塑膠被選擇來用於與一熱固性聚合物複合物共固化，以及一第二熱塑性塑膠(可是相同的熱塑性塑膠或不是相同的熱塑性塑膠)同樣被選擇用於該功能性組件。如上面所描述的，對於在該熱固性聚合物複合物形成表面的熱塑性塑膠的最理想的選擇是透過緊密地使該熱塑性塑膠和未固化的熱固性聚合物組件的複雜的溶解度參數匹配而達到的。該技術可被成功地用於選擇一候選的具有可達到的高連接強度的非晶性或半晶性聚合物。根據本發明的較佳形式的該方法適 合用於具有未固化的熱固性聚合物複合物組件。如在第2圖中顯示的，一個例子是在一高壓釜內的預浸纖維(預浸體)的固化。一堆預浸體10被放在一固化工具12上，以及熱塑性塑膠14的不連續的區域被放在最外層表面上。大體上方便的是使該熱塑性塑膠形成膜的形式。該經組合的預浸體和熱塑性塑膠繼而理想地被覆蓋在一多孔膜16和通風材料18內，並且透過一密封帶22，一尼龍裝袋膜20被密封至該工具。在被放在一高壓釜內之前，經由一真空入口24，該整個總成繼而被排空。該總成的溫度和壓力下被提升，並且被提升至一溫度，在此溫度下溶液相容性是使得能發生該等未固化熱固性聚合物組件遷移進入該熱塑性塑膠內，也就是該熱固性和熱塑性聚合物的相互滲透發生至一充分的深度來達到在所產生的形成表面的組件中的高的接頭的強度。遷移的溫度可是該熱固性聚合物的固化溫度。可是，在這個溫度下該等未固化的聚合物組件的不充分的遷移會發生，一較低的溫度停留可被包括在該固化迴圈內來增加該相互滲透區域。在該熱固性聚合物的固化之後，該總成被冷卻並且從該高壓釜中被移開，得到具有至少一部分地熱塑性表面的熱固性聚合物複合物。
上面描述的用於該固化和在一熱塑性聚合物複合物上的熱塑性塑膠的表面整合的技術沒有被限制在預浸體複合物的高壓釜固化，並且是可用很多其他熱固性複合物製造方法來對疊層和固化程序進行修改而被完成的，如果在該熱固性聚合物的固化之前，該等未固化的熱固性聚合物組件可與該熱塑性塑膠接觸，該等未固化的熱塑性聚合物組件的遷移是能發生的。
用於該功能性組件熔接表面的該熱塑性塑膠被要求實現幾個不同的目的。該熱塑性塑膠必須具有與該熱固性聚合物複合物的表面熱塑性塑膠的摻合或溶液相容性。在該等熱塑性塑膠和該選擇的熔接方法之間也必須具有相容性，藉此在這個相的期間，充分的分子混合能發生。最終地，取決於該功能性組件的設計，該熱塑性塑膠應具有充分地高的主體機械性能來操作其所欲的作用。對於在該熱固性聚合物複合物的表面上的該熱塑性塑膠，摻合和溶液相容性大體上會透過選擇一等同的熱塑性塑膠來確保。可是，並不是所有的熱塑性塑膠會很好的符合高頻連接操作；特別是，由一些半晶性熱塑性塑膠製造的部分可能遭受具有特殊幾何學的機械損壞，危及它們後面的功能。由於這個原因以及由於該功能性組件的有效的操作，必要的是選擇不同的熱塑性塑膠用於該功能性組件和熱固性聚合物複合物表面。很多不同的非晶性熱塑性塑膠被瞭解在高頻熔接操作中是可相容的。在高頻熔接操作中被瞭解是可相容的非晶性熱塑性材料包括PEI和ABS、PMMA和ABS以及PPO和PS。在高頻熔接操作中較少的半晶性熱塑性塑膠被瞭解是可相容的，例子是PET和PEI，以及PET和PC。
功能性組件的例子在第3圖中被顯示。第3A圖顯示一熱塑性功能性組件30，具有用於連接至一熱固性聚合物複合物的熱塑性表面的一較低的表面32，以及一功能性末端34，在此例子中是一螺紋柱，是用於不同的用途。該連接表面32具有多個突出來輔助在高頻熔接時的經控制的加熱，尤其是超音波熔接。在高頻迴圈位移下這些突出比臨近的熱塑性塑膠會更快地變熱。在本發明的第一具體例被利用中，該等突出的高度較佳地是小於或等於在該熱固性複合物化合物上的該熱塑性塑膠的厚度。可是，該等突出的高度會需要被保持在大約與在該熱固性聚合物複合物上的熱塑性表面的厚度相同，是為了得到最佳的熔接強度。一最小的推薦的在該熱固性複合物組件的表面上的熱塑性塑膠的厚度是20μm，而最大的熱塑性附近的厚度被重量、尺寸和成本的實際所限制，以及對於本發明的性能較佳地是不超過5mm。當該等突出在高度上類似於或等同於在該複合物組件上的該熱塑性層的厚度時，可能的是得到在該功能性組件和該複合物的熱塑性表面之間的幾乎是無縫的連接，而提供最大的連接強度。一不同的方法被要求用於本發明的該第二具體例，其中一聚合性塗層是位於該功能性組件的該熱塑性塑膠和在該熱固性複合物組件上的該熱塑性塑膠之間。為了得到一有效的熔接，在該熔接操作中該塗層必須被移開。在使用這些突出的場合中，它們必須具有充分的高度，如此被移開的塗層可被容納在該功能性組件和該熱固性複合物組件之間的空隙。較佳的是該等突出的高度大於覆蓋在該熱固性聚合物複合物組件表面上的熱塑性層的該聚合性塗層的厚度。儘管連接可由較短的突出得到，就方法的韌性，至少0.5mm的一突出的高度是被推薦的。
在需要來自該功能性組件的特殊性質的情況中，可較佳的是使該組件的一部分是由一金屬製造的。這樣的組件的一個例子是在第3B圖中顯示的一組件。這個功能性組件36的該金屬部分38可由機器製成、澆鑄或類似的方法而被製造。該包圍該功能性組件的金屬部分38的熱塑性塑膠40的製造是經由在一射出模內金屬部分38的覆蓋射出而被之後達到的。該組件具有的優點是具有一熱塑性熔接介面、對該組件的該金屬部分的連接強度和一功能性金屬部分，而達到本發明的該等目的。一類似的功能性組件42在第3C圖中顯示，是由金屬和熱塑性塑膠製造的。在這個例子中，該熱塑性部分44和金屬部分46可被分開地製造並且在之後被裝配。這個例子組件的基底在第3D圖中被圖示顯示，具有一帶有錐形超音波熔接導能器的熱塑性基底48。該金屬組件46會理想地被設計用於裝配至一複合物組件，藉此當開始接觸時，它與該複合物組件間有一特定的間隙，並且接下來熔接操作的完成可與該複合物組件接觸。
用於這樣的功能性組件的材料沒有被限制在金屬和熱塑性塑膠或加強熱塑膠。功能性組件也可具有一陶瓷部分，包括電子零件，或包括種種其他材料。可是，該等功能性組件應保留一熱塑性塑膠部分，該熱塑性塑膠以透過本發明描述的方式使它們被連接至該熱固性聚合物複合物組件。
使該功能性組件連接到該熱固性聚合物複合物組件上的一種方法是使用一高頻迴圈位移系統，諸如具有焊頭的超音波熔接機。熔接操作的例子在第4圖中顯示。一熱固性聚合物複合物組件50，是根據在本發明的第一具體例中的一較佳方法而製造的，在該組件的區域上它具有一熱塑性表面52。一功能性組件54，是根據本發明的方法被選擇及/或被設計的，該功能性組件54與其熱塑性表面56被放置在與該複合物組件50的熱塑性表面52相對的位置。一超音波熔接機焊頭58繼而被帶來面對該功能性組件54的頂面60，藉此壓力經由該熔接機焊頭58被施加到配對該功能性組件54和複合物組件50的熱塑性表面52、56。在當前的例子中，該超音波熔接機焊頭58具有一凹陷部分62來容納該功能性組件54的柱64。一高頻迴圈位移繼而被傳遞至該功能性組件，藉此首先在該組件中的該導能器66和繼而至少一些該等臨近的熱塑性材料加熱和熔化，導致該功能性組件熱塑性表面56和複合物熱塑性表面52的最終混合。典型地該方法會發生持續在0.5秒至10秒之間，取決於諸如振幅和頻率的因素。該迴圈位移繼而被停止，當冷卻時，該總成繼續被結合在一起。諸如旋轉熔接的摩擦反復可選擇性地被使用來在該功能性組件的該等熱塑性突出和該複合物組件的該熱塑性表面之間產生局部熱。熱塑性突出的用途對於摩擦熔接不是絕對必要的，但是對於提供一經控制的熔接方法是較佳的。
在一聚合性材料中透過諸如塗漆、粉末塗覆、噴霧、浸漬、刷、黏附貼布的技術或其他任何方式被塗覆而提供在一組件表面上的薄聚合物層的情況下，該方法可類似地被操作的。在後面的正文中，塗漆被用來被廣泛地參照該等技術之一或一類似的提供在一組件表面上的聚合物層的方法。熔接操作的一個例子在第5圖中被顯示。一熱固性聚合物複合物組件70，在該組件的一區域上具有一熱塑性表面72，並且接下來具有一被施加的聚合性材料塗層74。一功能性組件76是根據本發明的方法被選擇及/或被設計的，與其熱塑性表面78被放置在與該複合物組件的經塗漆的熱塑性表面80相對的位置。
在多個突出被利用作為本發明的該第二具體例的部分中，這些突出會更便利地位於該功能性組件上。在一較佳具體例中，一超音波熔接機焊頭84繼而被帶入與該功能性組件76的頂面86相對，藉此壓力經由該熔接機焊頭84被施加導該功能性組件76的該突出熱塑性表面78。在迴圈相對位移下，該功能性組件76的該突出熱塑性塑膠82移動在該熱塑性塑膠72上的塗料80，使它離開該突出熱塑性塑膠82的尖端。最終，該功能性組件76的該突出熱塑性塑膠82會與下面的該熱固性複合物組件70的熱塑性表面72接觸。另一方面，熔接以如在本發明的第一具體例中相同的方式發生。在一功能性組件的該熔接表面上的突出在除去一旋轉熔接操作中的漆是類似地有用的。在這種情況下，該等突出可挖去或刮去被塗漆的表面來顯露下面的熱塑性表面，該等突出繼而經由摩擦熱的產生而被熔接。
在該功能性組件以上面的方式被熔接的情況下，一熔接大體上會被達到，但是該組件可能未被準確地定位。在高頻振動下，諸如在超音波熔接中發現的，對於該功能性組件和該熱固性複合物積層物或組件有一有關彼此橫向移動的趨勢。在該功能性組件和超音波焊頭之間的橫向移動可被在該功能性組件上的上介面(也就是與該超音波焊頭接觸的表面)的形狀控制。有關該熱固性聚合物複合物組件的該超音波熔接機和功能性組件的橫向移動的控制也可被達到。一種方法是提供一限動器，它臨時地或永久地位於該複合物組件上，在該熔接操作中允許該功能性組件的垂直移動，但是阻止相當大的水平移動。第二種方法是使用諸如在第6圖中顯示的儀器。第6A圖圖示顯示了一功能性組件90、一熱固性聚合物複合物組件92和一超音波熔接機94的部分。此外，用於向該功能性組件或熱固性聚合物複合物組件定位或施加壓力的一結構被顯示為一遮板96，該遮板96與該超音波熔接機94連接，在某種程度上藉此該遮板96不與該超音波熔接焊頭98直接接觸。該遮板96可被用來抵抗在該超音波熔接機94和該熱固性複合物組件92之間的橫向移動。在該圖中的部分顯示的該遮板96是環形的，具有一內壁100、外壁102和適合於製造一密封縫的柔軟的基底材料104。該柔軟的基底材料104也可被用於使對這該熱固性複合物組件92的該遮板的振動減幅，並且為達到這個目的該柔軟的基底材料104可是黏的或特別地被成形或被構造來控制該表面或使振動減幅。該遮板96可被帶入與該熱固性複合物組件92接觸，並且在該內壁102和該外壁104之間的空氣被排出。這樣阻止了該超音波熔接機94向該熱固性複合物組件92的橫向移動。有利地，該遮板96也可被設計，藉此一淨下壓力被施加到與該熱固性複合物組件92有關的該超音波熔接機94上，它能有助於該熔接方法。
一類似的儀器在第6B圖中被顯示，它允許在一不平的表面上熔接並且允許該熔接焊頭的最佳定位。該功能性組件110、熱固性複合物組件112和超音波熔接儀器114是如上所描述的。被連接到該超音波熔接機套管116的是一個或多個柱118，在某種程度上藉此該等柱118不直接與該超音波焊頭120接觸。該等柱118具有一凹陷構造和一適合於製造一密封縫的柔軟的基底材料122。該等柱118能相對於該超音波熔接儀器114垂直滑動，藉此一彎曲的或有角的熱固性複合物組件112可與所有柱118在熔接的時候接觸。在熔接之前，當該等柱118被調整到所欲的高度，該等柱118的高度可相對於該超音波熔接機114被鎖住。接下來，在該等柱內的空氣被排出，導致一抵抗在該超音波熔接機114和熱固性複合物組件112之間的橫向移動和在該功能性組件110上的淨下壓力的施加的抗力。
其他可被使用的定位(locating)或定位(positioning)裝置包括導向裝置，該導向裝置可透過真空、夾子或可除去的膠粘劑被暫時地連接到該熱固性複合物組件，並且扮演用於該焊頭或該熔接機的一導向或定位裝置。
該等上面的熔接儀器的例子僅僅是示例性的，並且可透過在本發明中列出的原理的改變而達到。
實驗討論
具有一熱塑性表面的熱固性聚合物複合物板是根據本發明的該第一具體例被製造的，是透過在一堆包含T300碳纖維和Hexcel F593環氧樹脂的經預浸滲的平紋織物上放置一254 μm PVDF熱塑性膜的層而被製造的。該堆被放在一平的工具上並且用一真空包被圈住。在該真空包中的空氣被排除，並且該堆接下來在177℃和0.63MPa的外壓下固化120分鐘。固化之後，該熱塑性層可強烈地連接到該聚合物基材上。一表示一具有20×20mm表面接觸區域的功能性組件(由PVDF聚合物製造)之類似形狀，是被製造以用於在一表面上的超音波熔接，且是透過在該聚合物嵌段的一表面上水平地與垂直地製成具有60°接觸角的三角槽而製造出的。該結果是在該等功能性組件所一表面上的一系列的錐形突出，它們具有0.5mm的高度和0.58mm間距。在用丙醇清洗之後，該經製造的功能性組件表面和該熱固性複合物積層物的該熱塑性表面被一起帶入，並且被放在一超音波熔接機下，在20kHz的頻率下被操作。一約0.2MPa的壓力被施加到該熔接機焊頭並且因此被施加到該功能性組件。在施加超音波振動歷時3秒並且在壓力冷卻下之後，該功能性組件被牢固地向該熱固性聚合物複合物組件固定。接下來的拉測試顯示5MPa的連接強度。
具有熱塑性表面的一第二熱固性聚合物複合物板是根據本發明的該第二具體例製造的，是透過在一堆包含T300碳纖維和Cycorn 970環氧樹脂的經預浸滲的平紋織物上放置一254μm PVDF熱塑性膜的層而被製造的。該堆被放在一平的工具上並且用一真空包被圈住。在該真空包中的空氣被排除，並且該堆接下來在177℃和0.63MPa的外壓下固化120分鐘。固化之後，該熱塑性層可強烈地連接到該聚合物基材上。包括該熱塑性表面的板繼而使用Akzo Nobel Aerodur Primer 37045和Akzo Nobel Aerodur Finish C21/100聚胺酯搪瓷被塗漆。一表示一具有20×20mm表面接觸區域的功能性組件(由PVDF聚合物製造)之類似的形狀，是被製造以用於在一表面上的超音波熔接，且是透過在該聚合物嵌段的一表面上水平地與垂直地製成具有60°接觸角的三角槽而製造出的。結果是在該等功能性組件所一表面上的一系列的錐形突出，它們具有1.7mm的高度和2mm間距。該經機器製造的功能性組件表面和該熱固性複合物積層物的該熱塑性表面被一起帶入，並且被放在一超音波熔接機下，在20kHz的頻率下被操作。一約1MPa的壓力被施加到該熔接機焊頭並且因此被施加到該功能性組件。在施加超音波振動歷時1秒並且在壓力冷卻下之後，該功能性組件被牢固地向該熱固性聚合物複合物組件固定。後面的檢查顯示該功能性組件的該熱塑性塑膠已經直接連接到該複合物組件的該熱塑性表面上。接下來的拉測試顯示3MPa的連接強度。
10．．．預浸體
12．．．固化工具
14．．．熱塑性塑膠
16．．．多孔膜
18．．．通風材料
20．．．尼龍裝袋膜
22．．．密封帶
24．．．真空入口
30．．．熱塑性功能性組件
32．．．表面
34．．．功能性末端
36．．．功能性組件
38．．．金屬部分
40．．．熱塑性塑膠
42．．．功能性組件
44．．．熱塑性部分
46．．．金屬部分
48．．．熱塑性基底
50．．．熱固性聚合物複合物組件
52．．．熱塑性表面
54．．．功能性組件
56．．．熱塑性表面
58．．．超音波熔接焊頭
60．．．頂面
62．．．凹陷部分
64．．．柱
66．．．導能器
70．．．熱固性聚合物複合物組件
72．．．熱塑性表面
74．．．聚合性材料塗層
76．．．功能性組件
78．．．熱塑性表面
80．．．經塗漆的熱塑性表面
82．．．突出熱塑性塑膠
84．．．超音波熔接機焊頭
86．．．頂面
90．．．功能性組件
92．．．熱固性聚合物複合物組件
94．．．超音波熔接機
96．．．遮板
98．．．超音波熔接焊頭
100．．．內壁
102．．．外壁
104．．．柔軟的基底材料
110．．．功能性組件
112．．．熱固性複合物組件
114．．．超音波熔接機
116．．．超音波熔接機套管
118．．．柱
120．．．超音波焊頭
122．．．柔軟的基底材料
第1圖說明一聚合物的Hansen溶解度圖，該圖可被用於測量一溶劑對於一特別的聚合物的溶解度；第2圖是在高壓釜固化之前熱固性聚合物複合物預浸體和熱塑性膜的一示意圖；第3A圖是一由熱塑性塑膠或加強熱塑膠製成的一普通的功能性組件或配件的示意圖；第3B圖是一由一具有熱塑性塑膠封閉的基底的金屬組件製成的一普通的功能性組件或配件的示意圖；第3C圖是一由被插入一熱塑性基底內的一金屬組件製成的一普通的功能性組件或配件的示意圖；第3D圖是第3C圖的一底面圖，顯示出一部分金屬基底和在該熱塑性基底中的金字塔形狀的導能器；第4圖是一功能性組件或類似於3B的配件、一具有一熱塑性表面的固化的熱固性複合物組件和一熔接儀器的較低部分的示意圖；第5圖是一功能性組件或類似於3B的配件、一具有一具有聚合性塗層的一熱塑性表面的固化的熱固性複合物組件和一熔接儀器的較低部分的示意圖；第6A圖是一功能性組件或類似於3B的配件、一具有一熱塑性表面的固化的熱固性複合物組件和一具有一環狀真空遮板的熔接儀器的較低部分的示意圖；及第6B圖是一功能性組件或配件、一具有一熱塑性表面的固化的熱固性複合物和一具有可調節真空管的熔接儀器的較低部分的示意圖。
90．．．功能性組件
92．．．熱固性聚合物複合物組件
94．．．超音波熔接機
96．．．遮板
98．．．超音波熔接焊頭
100．．．內壁
102．．．外壁
104．．．柔軟的基底材料

Claims (15)

  1. 一種使一功能性組件結合至一熱固性聚合物複合物組件的方法，該熱固性複合物組件包含一熱固性聚合物複合物材料，以及在至少部分要被結合的表面上的一熱塑性聚合物層，該方法包括該等如下步驟：透過該等如下步驟，將該熱塑性層形成在該熱固性聚合物複合物組件上：選擇未固化的熱固性聚合物複合物樹脂構件和一第一熱塑性聚合物，它們具有表示該熱塑性聚合物和未固化熱固性聚合物樹脂構件相互滲透能力的Hansen溶解度參數；使該熱塑性聚合物位於與該未固化的熱固性聚合物複合物組件接觸的位置，藉此當被固化時至少一部分的該複合物組件的一表面是由該熱塑性聚合物構成；使該熱塑性聚合物和未固化熱固性聚合物複合物組件加熱至該熱固性聚合物的固化溫度，在該熱固性聚合物固化之前，該等未固化的熱固性聚合物樹脂構件和該熱塑性聚合物能至少部分地相互滲透；以及使該熱塑性聚合物和固化的熱固性聚合物組件冷卻，藉此該熱塑性聚合物係非常強烈地被連接到該固化的熱固性聚合物組件；該方法進一步包括該等如下步驟：選擇一功能性組件，該功能性組件具有至少在要被結合的表面上的一第二熱塑性聚合物，該第二熱塑性聚合物是被選擇以使得它在高頻振盪相對位移或高速連 續相對位移熔接操作中可與該熱固性聚合物複合物組件的熱塑性表面形成高強度接頭；使該複合物組件的該熱塑性表面位於與該功能性組件的熱塑性表面緊密接觸的位置；在該熱固性聚合物複合物組件和該功能性組件之間施加一高頻振盪相對位移或高速連續相對位移，藉此該等組件的該等各自的熱塑性表面的至少一部分是至少部分地熔化和熔融；停止該高頻振盪相對位移或高速連續相對位移，並且使該熱固性聚合物複合物組件和該功能性組件以一固定的關係保持在一起，藉此該熔化的熱塑性塑膠或該等熔化的熱塑性塑膠再凝固並且該等組件被熔接在一起。
  2. 如申請專利範圍第1項所述之方法，其中在該功能性組件或熱固性聚合物複合物組件之至少一者上的該熱塑性表面是被成型有一個或多個突出。
  3. 如申請專利範圍第2項所述之方法，其中在該功能性組件上的熱塑性表面突出的高度是小於或等於在該熱固性聚合物複合物組件上的熱塑性塑膠的厚度。
  4. 一種使一功能性組件結合至一經塗覆的熱固性聚合物複合物組件的方法，該熱固性聚合物複合物組件包含一熱固性聚合物複合物材料，與在要被結合的表面的至少該部分上的一熱塑性聚合物層和一覆蓋該熱塑性聚合物層的聚合性塗層，該方法包括該等如下步驟：透過該等如下步驟形成一經塗覆的熱固性聚合物 複合物：選擇未固化的熱固性聚合物複合物樹脂構件和一第一熱塑性聚合物，它們具有表示該熱塑性聚合物和未固化熱固性聚合物樹脂構件相互滲透能力的Hansen溶解度參數；使該熱塑性聚合物位於與該未固化的熱固性聚合物複合物組件接觸的位置，藉此當被固化時至少一部分的該複合物組件的一表面是由該熱塑性聚合物構成；使該熱塑性聚合物和未固化熱固性聚合物複合物組件加熱至該熱固性聚合物的固化溫度，在該熱固性聚合物固化之前，該等未固化的熱固性聚合物樹脂構件和該熱塑性聚合物能至少部分地相互滲透；使該熱塑性聚合物和固化的熱固性聚合物組件冷卻，藉此該熱塑性聚合物係非常強烈地被連接到該固化的熱固性聚合物組件；以及用一聚合性材料層塗覆該含有熱塑性表面的熱固性聚合物組件；該方法進一步包括如下步驟：選擇一功能性組件，該功能性組件具有至少在要被結合的表面上的一第二熱塑性聚合物，該第二熱塑性聚合物是被選擇以使得它在高頻振盪相對位移或高速連續相對位移熔接操作中可與在該熱固性聚合物複合物組件的聚合性塗層之下的熱塑性表面形成高強度接頭；使該複合物組件的該熱塑性表面位於與該功能性 組件的該經塗覆的熱塑性表面緊密接觸的位置；在該熱固性聚合物複合物組件和該功能性組件之間施加一高頻振盪相對位移或高速連續相對位移，藉此在該熱塑性表面之上的該聚合性材料塗層的至少一部分被移開並且該等組件的該等各自的熱塑性表面的至少一部分接觸、熔化和熔融；停止該高頻振盪相對位移或高速連續相對位移，並且使該熱固性聚合物複合物組件和該功能性組件以一固定的關係保持在一起，藉此該熔化的熱塑性塑膠或該等熔化的熱塑性塑膠再凝固，並且該等組件被結合在一起。
  5. 如申請專利範圍第4項所述之方法，其中在該功能性組件上的該熱塑性表面被成型有一個或多個突出。
  6. 如申請專利範圍第5項所述之方法，其中在該功能性組件上的該等熱塑性表面突出具有一大於覆蓋在該熱固性複合物組件表面上的該熱塑性層的聚合性材料塗層的厚度的高度。
  7. 如申請專利範圍第6項所述之方法，其中在該功能性組件上的該等熱塑性表面突出的高度至少是0.5mm。
  8. 如申請專利範圍第1項或第4項所述之方法，其中該功能性組件或熱固性聚合物複合物組件表面的該熱塑性聚合物是選自由一純的熱塑性聚合物、一共聚物或一聚合物摻合物構成之群組。
  9. 如申請專利範圍第1項或第4項所述之方法，其中在該複合物組件上的該熱塑性層的厚度至少是20微米且少於 5mm。
  10. 如申請專利範圍第1項所述之方法，其中在高頻振盪相對位移的施加之前，包含一熱塑性聚合物的一額外的層被包括在該熱固性聚合物複合物組件和功能性組件之間。
  11. 如申請專利範圍第1項或第4項所述之方法，其中多於一個的功能性組件被結合至該熱固性聚合物複合物。
  12. 如申請專利範圍第1項或第4項所述之方法，其中該功能性組件或熱固性聚合物複合物組件表面的該熱塑性聚合物被歸類為一半晶性聚合物或非晶性聚合物。
  13. 如申請專利範圍第1項或第4項所述之方法，其中在該熱固性複合物組件上的該第一表面熱塑性聚合物是一與在該功能性組件上的該第二熱塑性聚合物不同的熱塑性聚合物。
  14. 如申請專利範圍第1項或第4項所述之方法，其中在該熱固性複合物組件或該功能性組件上的該熱塑性聚合物是PVDF，或者二者都是PVDF。
  15. 一種熱固性聚合物複合物組件，具有一功能性組件，該功能性組件是透過如申請專利範圍第1至7項及第10項中任一項所述之方法而被連接的。
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