WO2021232795A1 - 换能器、其组装方法及超声波焊接装置 - Google Patents

换能器、其组装方法及超声波焊接装置 Download PDF

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Publication number
WO2021232795A1
WO2021232795A1 PCT/CN2020/139977 CN2020139977W WO2021232795A1 WO 2021232795 A1 WO2021232795 A1 WO 2021232795A1 CN 2020139977 W CN2020139977 W CN 2020139977W WO 2021232795 A1 WO2021232795 A1 WO 2021232795A1
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WIPO (PCT)
Prior art keywords
piezoelectric vibrator
screw
wire
electrode sheet
transducer
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PCT/CN2020/139977
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English (en)
French (fr)
Inventor
颜炳姜
王成勇
李伟秋
何吉峰
何渐坚
陆劲波
Original Assignee
汇专科技集团股份有限公司
科益展智能装备有限公司
科益展智能装备有限公司广州分公司
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Publication of WO2021232795A1 publication Critical patent/WO2021232795A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B06—GENERATING OR TRANSMITTING MECHANICAL VIBRATIONS IN GENERAL
    • B06B—METHODS OR APPARATUS FOR GENERATING OR TRANSMITTING MECHANICAL VIBRATIONS OF INFRASONIC, SONIC, OR ULTRASONIC FREQUENCY, e.g. FOR PERFORMING MECHANICAL WORK IN GENERAL
    • B06B1/00—Methods or apparatus for generating mechanical vibrations of infrasonic, sonic, or ultrasonic frequency
    • B06B1/02—Methods or apparatus for generating mechanical vibrations of infrasonic, sonic, or ultrasonic frequency making use of electrical energy
    • B06B1/06—Methods or apparatus for generating mechanical vibrations of infrasonic, sonic, or ultrasonic frequency making use of electrical energy operating with piezoelectric effect or with electrostriction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic 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
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations

Definitions

  • This application relates to the technical field of ultrasonic processing equipment, for example, to a transducer, an assembling method thereof, and an ultrasonic welding device including the transducer.
  • the ultrasonic welding system is suitable for all plastic nose bridge welding, post-folding welding, breathing valve welding, multi-layer seam welding and ear band welding of masks and medical protective clothing. It is also suitable for welding diapers, packaging bags or metal materials.
  • the ultrasonic welding system includes an ultrasonic generator, a transducer, a horn and a welding head.
  • the general working principle is: the ultrasonic generator converts low-frequency alternating current into high-frequency alternating current, and converts electrical energy into high-frequency vibration mechanical energy through the transducer When the welding head acts on the contact surface of the thermoplastic, it produces tens of thousands of high-frequency vibrations per second. The high-frequency vibration transmits ultrasonic energy to the welding area through the upper weldment.
  • the upper weldment and the lower weldment in this area generate friction. After the local high temperature is generated, the pressure lasts for a few seconds after the ultrasonic action, so that the upper weldment and the lower weldment are solidified and formed to form a strong molecular chain to realize ultrasonic welding.
  • the ultrasonic welding system When the ultrasonic welding system is used for welding masks, diapers, packaging bags or metal materials, it does not require solvents, adhesives or other auxiliary materials. It is safe, environmentally friendly and pollution-free, and replaces traditional manual welding. It can not only improve production efficiency, but also be effective reduce costs.
  • the transducer usually includes a screw and a piezoelectric vibrator sleeved on the outside of the screw.
  • a heat shrink tube is usually sleeved between the screw and the piezoelectric vibrator in the related art;
  • the transducer will generate high temperature (such as high temperature higher than 90°C) during operation, and the high temperature will cause the heat shrinkable insulation tube to continue It is easy to be pierced by the external thread of the screw during the shrinking process, so that the high voltage on the electrode sheet will break through the air and generate an arc with the screw.
  • the mask is welded directly by ultrasonic high-frequency vibration, so the leaking welding head will cause the mask produced by ultrasonic welding to produce quality defects on the mask and the ear strap or the mask body.
  • the electrode sheet is used to conduct the positive or negative electrode of the piezoelectric ceramic.
  • the pins on the electrode sheet are usually flush with the board surface, and the whole is in the shape of a flat plate.
  • the present application provides a transducer, which can avoid the occurrence of electric leakage due to electric arc generated between the electrode sheets and the screw of the transducer during the working process, and reduce the probability of ignition between the electrode sheets.
  • a transducer comprising: a front cover plate; a screw rod, the front end of the screw rod is connected to the front cover plate; a piezoelectric vibrator sleeved on the outside of the screw rod and located at the rear end of the front cover plate; and The rear cover is sleeved on the outside of the screw and located at the rear end of the piezoelectric vibrator.
  • the piezoelectric vibrator is compressed between the front cover plate and the rear cover plate, and a Teflon insulating sleeve is provided on the outer circumference of the screw relative to the piezoelectric vibrator, so that the Maintain insulation between the screw and the piezoelectric vibrator;
  • the piezoelectric vibrator includes a plurality of piezoelectric ceramics and a plurality of electrode plates arranged in a stacked structure, each of the electrode plates is connected with a wire, the electrode plate includes: an electrode plate body, sleeved on the screw And pins, which are provided on the outer edge of the electrode sheet body, the pins include at least one crimping plate, and the crimping plate defines a wire groove by bending.
  • one end of the wire passes through the wire slot and is electrically connected to the electrode sheet, and the outer surface of the connection position of each wire and the electrode sheet is coated with insulating glue.
  • the length of the Teflon insulating sleeve in the axial direction is greater than the length of the piezoelectric vibrator in the axial direction.
  • the thickness of the Teflon insulating sleeve is 0.5 mm-1 mm.
  • the pin includes at least two crimping plates arranged side by side, and two adjacent crimping plates are bent in opposite directions; the wire grooves of each crimping plate are correspondingly connected.
  • the part of the wire located in the wire groove is welded to the crimping plate.
  • An ultrasonic welding device includes: the above-mentioned transducer; an horn, the rear end of the horn is connected with the front end of the front cover plate; and a welding head installed at the front end of the horn.
  • a method for assembling a transducer includes:
  • a Teflon insulating sleeve is sleeved on the outer circumference of the screw at the rear end of the front cover plate;
  • the electrode sheet includes an electrode sheet body and pins arranged on the outer edge of the electrode sheet body, the pins are bent to form at least one crimping plate, and the crimping plate defines a wire groove;
  • a wire is inserted into the wire slot of each electrode sheet to make the wire and the electrode sheet realize electrical connection, and the outer surface of the connection between the wire and the electrode sheet is coated with insulation glue.
  • the above-mentioned assembling method of the transducer further includes: detecting whether the insulation resistance between the screw and the piezoelectric vibrator satisfies a preset condition.
  • the detecting whether the insulation resistance between the screw and the piezoelectric vibrator satisfies a preset condition includes: applying a voltage of 2000V-3000V between the screw and the piezoelectric vibrator, if the The insulation resistance between the screw and the piezoelectric vibrator is greater than 450 M ⁇ , that is, the preset condition is satisfied.
  • the above-mentioned assembling method of the transducer further includes: coating the outer peripheral wall of the piezoelectric vibrator with conformal paint.
  • the method for assembling the aforementioned transducer further includes: detecting whether the frequency, impedance, and capacitance of the piezoelectric vibrator meet preset conditions.
  • the coating a conformal paint on the outer peripheral wall of the piezoelectric vibrator includes: drying the transducer in an environment of 55° C.-65° C. for 20 min-40 min, and then at a humidity of less than 50% In an environment, the conformal paint is coated on the outer peripheral wall of the piezoelectric vibrator.
  • the above-mentioned assembling method of the transducer further includes: welding the part of the wire located in the wire groove to the crimping plate.
  • a Teflon insulating sleeve is provided between the piezoelectric vibrator and the screw, which can ensure that the piezoelectric vibrator and the screw are insulated from each other and prevent the transducer from working
  • the high voltage at the time of time punctures the air and Teflon insulation sleeves to avoid arcing and effectively prevent leakage;
  • the lead of the electrode sheet is formed by bending at least one crimping plate, and the crimping plate is bent to limit energy in it.
  • the wire slot for the wire to pass through can ensure that a fixed distance between two adjacent electrode pieces is maintained. Compared with the pure solder connection in the related technology, it can avoid the distance between the adjacent electrode pieces when the solder is melted at high temperature. Reduced, thereby effectively reducing the probability of sparking between adjacent electrode sheets.
  • Figure 1 is a perspective view of an embodiment of the transducer of the present application
  • Figure 2 is a longitudinal sectional view of the embodiment shown in Figure 1;
  • FIG. 3 is a schematic diagram of the structure of an electrode sheet of an embodiment of the transducer of the present application.
  • FIG. 4 is a partial schematic diagram of the connection relationship between the electrode sheet and the wire in an embodiment of the transducer of the present application
  • Figure 5 is a perspective view of an embodiment of the ultrasonic welding device of the present application.
  • Fig. 6 is a schematic flow chart of an embodiment of a method for assembling a transducer of the present application.
  • Transducer 1. Front cover; 2. Screw; 3. Piezoelectric vibrator; 31. Piezoelectric ceramic; 32. Electrode plate; 321. Electrode plate body; 322. Pin; 3221. Curl Plate; 3222, wire slot; 323, positive electrode sheet; 324, negative electrode sheet; 4. back cover plate; 5. Teflon insulating sleeve; 6, wire; 7, nut; 20, horn; 30, Welding head.
  • front end and “rear end” mentioned in this article respectively refer to: in the processing process, the near processing end is the “front end” and the far processing end is the “rear end”. They are relative concepts, and therefore It can be changed according to its different positions and different practical states. Therefore, these or other directions should not be used as restrictive terms.
  • first, second, etc. are used herein to describe a variety of information, but the information should not be limited to these terms, and these terms are only used to distinguish the same type of information from each other.
  • first information may also be referred to as “second” information
  • second information may also be referred to as “first” information.
  • the first aspect of the embodiments of the present application provides a transducer 10, which includes: a front cover 1, a screw 2, a piezoelectric vibrator 3, and a rear cover 4.
  • the front end of the screw 2 is connected to the front cover 1, the piezoelectric vibrator 3 is sleeved on the outside of the screw 2 and located at the rear end of the front cover 1, and the rear cover 4 is sleeved on the outside of the screw 2 and located on the piezoelectric vibrator 3. rear end.
  • the piezoelectric vibrator 3 is compressed between the front cover plate 1 and the rear cover plate 4, and the outer circumference of the screw 2 is provided with a Teflon insulating sleeve 5 at the position relative to the piezoelectric vibrator 3, so that the screw 2 and the piezoelectric vibrator The vibrators 3 are kept insulated from each other.
  • the Teflon material has high temperature resistance, mechanical wear resistance and excellent electrical insulation properties, so the transducer 10 In the case of working and generating high temperature, it can still ensure that the piezoelectric vibrator 3 and the screw 2 are insulated from each other, preventing the piezoelectric vibrator 3 from breaking through the air and the Teflon insulating sleeve 5 during operation, causing the screw 2 to generate arc leakage
  • the transducer 10 is used in an ultrasonic welding device, it can further prevent leakage of the welding head, thereby improving the production quality of masks and medical protective equipment.
  • the rear end of the screw 2 in this embodiment passes through the rear face of the rear cover plate 4, and a nut 7 is locked on the rear face of the screw 2, and the tightening of the nut 7 can compress and compress Electric vibrator 3.
  • the rear end of the screw 2 can be configured into a nut shape, that is, the screw 2 has a screw structure, and the piezoelectric vibrator 3 can be compressed by directly tightening the rear end of the screw 2. This specific embodiment is not specifically shown in the drawings. show.
  • the length of the Teflon insulating sleeve 5 in the axial direction is greater than the length of each piezoelectric vibrator 3 in the axial direction; in one embodiment, Teflon The dragon tube 5 extends from the rear end surface of the front cover 1 to the rear in the axial direction, and extends to exceed the total height of the piezoelectric vibrator 3.
  • the thickness of the Teflon insulating sleeve 5 is 0.5 mm-1 mm, which can ensure good insulation performance and is easy to install; in one embodiment, the thickness of the Teflon insulating sleeve 5 is about 0.75mm.
  • the piezoelectric vibrator 3 includes a plurality of piezoelectric ceramics 31 and a plurality of electrode plates 32 arranged in a stacked structure, wherein each electrode plate 32 is set to conduct each piezoelectric Ceramic 31; each electrode piece 32 is connected with a wire 6 (see Figure 4), the wire 6 and the electrode piece 32 are electrically connected, and the outer surface of the connection position of the wire 6 and the electrode piece 32 is coated with insulating glue (Not specifically shown in the drawings), the insulating glue is set to isolate the wire 6 and the electrode sheet 32 from the outside to achieve insulation; in one embodiment, the electrode sheet 32 that conducts the positive electrode surface of the piezoelectric ceramic 31 is the positive electrode.
  • the electrode sheet 32 that leads to the negative electrode surface of the piezoelectric ceramic 31 is the negative electrode sheet 324, and the adjacent positive electrode sheet 323 can be effectively reduced by placing insulating glue on the outer surface of the connection position between the lead 6 and the electrode sheet 32 Probability of sparking with the negative electrode sheet 324.
  • the opposite surfaces of the two adjacent piezoelectric ceramics 31 have the same polarity, so that the positive electrode surface or the negative electrode surface of the two adjacent piezoelectric ceramics 31 can be conducted through one electrode sheet 32.
  • the piezoelectric vibrator 3 includes four piezoelectric ceramics 31 and four electrode strips 32. The four electrode strips 32 are in order from front to back: positive electrode strip 323, negative electrode strip 324, positive electrode strip 323 and Negative electrode sheet 324.
  • a reasonable distance is usually reserved between two adjacent electrode plates 32 before the wire 6 is connected.
  • a predetermined width is extended in the axial direction, so that the distance between two adjacent electrode sheets 32 will be reduced, thereby increasing the probability of ignition between the positive electrode sheet 323 and the negative electrode sheet 324.
  • the electrode sheet 32 includes an electrode sheet body 321 and a pin 322.
  • the electrode sheet body 321 is sleeved on the outside of the screw 2, and the pin 322 is provided on the electrode.
  • the pins 322 include at least one crimping plate 3221.
  • the crimping plate 3221 is bent by using needle-nose pliers to form a semi-arc shape, so that a wire slot 3222 is reserved between the crimping plates 3221.
  • One end of the wire 6 is threaded through the wire slot 3222, as shown in FIG. 4 for details.
  • the wire groove 3222 is formed by bending the crimping plate 3221, and the wire 6 is inserted into the wire groove 3222. Therefore, the distance between two adjacent electrode sheets 32 is fixed and will not be caused by the subsequent soldering process.
  • the reduced distance can avoid the problem of reduced distance after the solder is melted at a high temperature, can effectively ensure the distance between two adjacent electrode plates 32, and reduce the probability of ignition.
  • the pin 322 includes at least two crimping plates 3221 arranged side by side. In order to make the connection more reliable, two adjacent crimping plates 3221 are bent in opposite directions, and the wire groove 3222 of each crimping plate 3221 is correspondingly connected.
  • Figures 3 and 4 only show a specific implementation in which the pin 322 includes three crimping plates 3221, and the crimping plates 3221 on both sides are bent toward the inner side, and the middle crimping plate 3222 is bent toward the outer side .
  • each curling plate 3221 in the same direction.
  • the part of the wire 6 located in the wire groove 3222 is soldered to the crimping plate 3221; since the space formed by the wire groove is small, only a small amount of solder is needed. After a small amount of solder is melted Being accommodated in the wire slot 3221, not only will the distance between the adjacent electrode sheets 32 not be reduced due to welding, but the solder will closely connect the wires and the electrode sheets, which can further ensure the conductivity between the wires and the electrode sheets.
  • the wire 6 and the electrode sheet 32 in this embodiment are connected by soldering.
  • the ultrasonic welding device includes an horn 20, a welding head 30, and the above-mentioned transducer 10.
  • the rear end of the horn 20 Connected with the front end of the front cover 1, the welding head 30 is installed at the front end of the horn 20.
  • the ultrasonic welding device in this embodiment includes the above-mentioned transducer, it has all the beneficial effects of the above-mentioned transducer, and will not be repeated here.
  • the third aspect of the embodiments of the present application proposes a method for assembling a transducer, as shown in FIG. 6 specifically, including:
  • the electrode sheet includes an electrode sheet body and pins provided on the outer edge of the electrode sheet body, and the pins are bent to form at least one crimping plate, and the crimping plate defines a wire groove;
  • a wire is respectively pierced in the wire groove of each electrode sheet to electrically connect the wire and the electrode sheet, and the outer surface of the connection between the wire and the electrode sheet is coated with insulating glue.
  • the Teflon insulating sleeve is arranged between the piezoelectric vibrator and the screw, it can maintain good insulation between the piezoelectric vibrator and the screw during the working process of the transducer, thereby preventing electric leakage; in addition, Since the pins of the electrode sheet are arranged in the form of being bent by the crimping plate, the electrical connection between the wire and the electrode sheet is realized by threading the wire in the wire slot formed by the bending of the crimping plate, and the electrical connection between the wire and the electrode sheet is realized. The outer surface of the connection part of the electrode plates is coated with insulating glue.
  • the distance between two adjacent electrode plates is fixed, the distance will not decrease with the subsequent soldering process. It is small, can avoid the problem of the pitch reduction caused by the high temperature melting of the solder, and can effectively reduce the probability of ignition.
  • the assembling method of the transducer in this embodiment further includes the step of detecting whether the insulation resistance between the screw and the piezoelectric vibrator meets a preset condition.
  • the following method is used to detect whether the insulation resistance between the screw and the piezoelectric vibrator satisfies a preset condition: a voltage of 2000V-3000V is applied between the screw and the piezoelectric vibrator, and if the voltage between the screw and the piezoelectric vibrator is The insulation resistance is greater than 450M ⁇ , that is, it meets the preset conditions.
  • a voltage of 2500V is applied between the screw and the piezoelectric vibrator. If the insulation resistance between the screw and the piezoelectric vibrator is greater than 500M ⁇ , it indicates that Insulation requirements.
  • Step S7 is to coat the outer peripheral wall of the piezoelectric vibrator with three-proof paint, which mainly plays a role of isolation.
  • the three-proof paint is applied by the following method: After the transducer is dried at 55°C-65°C for 20min-40min, the three-proof paint is applied to the piezoelectric vibrator in an environment with a humidity lower than 50% The peripheral wall. In one embodiment, the transducer is dried at a temperature of 60°C for 30 minutes.
  • connecting the wire on the electrode sheet further includes: welding the portion of the wire in the wire groove to the crimping plate. Since the space formed by the wire groove is small, only a small amount of solder is needed. The small amount of solder is melted and contained in the wire groove 3221, which not only does not reduce the distance between adjacent electrode plates 32 due to welding, but also The solder tightly connects the wire and the electrode sheet, which can further ensure the conductivity between the wire and the electrode sheet. In other embodiments, the wire and the electrode sheet are soldered by soldering.
  • a Teflon insulating sleeve is provided between the piezoelectric vibrator and the screw, which can ensure that the piezoelectric vibrator and the screw are kept between each other. Insulation, to prevent the high-voltage breakdown of the air and Teflon insulation sleeve when the transducer is working, and avoid arcing and effectively prevent leakage; in addition, because the pins of the electrode are set in the form of bending by the crimping plate, through The wire is inserted into the wire groove formed by the bending of the crimping plate to realize the electrical connection between the wire and the electrode sheet.

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Abstract

一种换能器（10）、其组装方法及超声波焊接装置，该换能器（10）包括：前盖板（1）；螺杆（2），所述螺杆（2）前端与所述前盖板（1）相连；压电振子（3），套设于所述螺杆（2）的外部且位于所述前盖板（1）的后端；后盖板（4），套设于所述螺杆（2）的外部且位于所述压电振子（3）的后端；其中，所述压电振子（3）压紧于所述前盖板（1）与所述后盖板（4）之间，所述螺杆（2）的外周相对于所述压电振子（3）的位置处设有铁氟龙绝缘套管（5），使得所述螺杆（2）与所述压电振子（3）之间保持绝缘。

Description

换能器、其组装方法及超声波焊接装置
本申请要求申请日为2020年5月18日、申请号为202010422040.0的中国专利申请的优先权，该申请的全部内容通过引用结合在本申请中。
技术领域
本申请涉及超声波加工设备技术领域，例如是涉及一种换能器、其组装方法及包括该换能器的超声波焊接装置。
背景技术
超声波焊接系统适用于口罩、医用防护服的全塑鼻梁条焊接、折边后焊接、呼吸阀焊接、多层滚焊和耳带焊接等焊接工序，也适用于纸尿裤、包装袋或金属材料的焊接工序。超声波焊接系统包括超声波发生器、换能器、变幅杆和焊接头，大致的工作原理为：超声波发生器将低频交流电转化为高频交流电，通过换能器将电能转化为高频振动的机械能，焊接头作用于热塑性塑料的接触面时产生每秒几万次的高频振动，高频振动通过上焊件把超声能量传送到焊区，此区域的上焊件和下焊件产生摩擦，产生局部高温，超声作用后，压力持续几秒，使上焊件和下焊件凝固成型，形成坚固的分子链，实现超声焊接。使用超声波焊接系统进行口罩、纸尿裤、包装袋或金属材料的焊接加工时，无需溶剂、粘贴剂或其他辅助物，安全、环保无污染，且替代传统人工焊接，不仅能够提高生产效率，而且能够有效降低成本。
换能器通常包括螺杆及套设在螺杆的外部的压电振子，为了使压电振子与螺杆之间保持彼此绝缘，相关技术中通常在螺杆与压电振子之间套设有热缩管；采用该换能器，特别是将上述换能器应用于超声波焊接时，存在以下问题：换能器在工作时会产生高温(比如高于90℃的高温)，高温会导致热缩绝缘管持续收缩，而在收缩过程中易被螺杆外的外螺纹穿破，使得电极片上的高压会击穿空气而与螺杆产生电弧，再通过变幅杆等传递给焊头，而产生漏电，而焊头是直接利用超声高频振动来焊接口罩的，故漏电的焊头会导致超声焊接加工出来的口罩在面罩与耳带或面罩本体上产生质量缺陷。
另外，在换能器中，电极片用于导通压电陶瓷的正极或者负极。相关技术中，电极片上的引脚通常与板面相平齐，整体呈平板状，在将每个压电陶瓷及 电极片压装于换能器上时，未焊接导线之前，相邻两电极片之间的间距比较合理，但是在每个电极片上焊接导线后，由于焊料(例如锡焊)熔融后会沿换能器的轴向流动从而具有一定的宽度，导致相邻两电极片之间的间距缩小，在换能器工作时，相邻的正电极片与负电极片之间可能出现高压打火的现象。
发明内容
本申请提供了一种换能器，能够避免工作过程中，换能器的电极片与螺杆之间产生电弧而发生漏电现象，并降低电极片之间的打火概率。
一种换能器，包括：前盖板；螺杆，所述螺杆前端与所述前盖板相连；压电振子，套设于所述螺杆的外部且位于所述前盖板的后端；及后盖板，套设于所述螺杆的外部且位于所述压电振子的后端。
其中，所述压电振子压紧于所述前盖板与所述后盖板之间，所述螺杆的外周相对于所述压电振子的位置处设有铁氟龙绝缘套管，使得所述螺杆与所述压电振子之间保持绝缘；
所述压电振子包括以叠堆构造布置的多个压电陶瓷和多个电极片，每个所述电极片上均连接有导线，所述电极片包括：电极片本体，套设于所述螺杆的外部；及引脚，设于所述电极片本体的外缘，所述引脚包括至少一个卷曲板，所述卷曲板通过弯折限定形成有线槽。
其中，所述导线的一端穿设于所述线槽内，与所述电极片电连接，每个所述导线与所述电极片的连接位置的外表面均涂覆有绝缘胶。
可选地，所述铁氟龙绝缘套管沿轴向的长度大于所述压电振子沿轴向的长度。
可选地，所述铁氟龙绝缘套管的厚度为0.5㎜-1㎜。
可选地，所述引脚包括至少两个并排设置的所述卷曲板，相邻两个所述卷曲板朝向相反的方向弯折；每个所述卷曲板的线槽对应连通。
可选地，所述导线位于所述线槽内的部分与所述卷曲板相焊接。
一种超声波焊接装置，包括：如上述的换能器；变幅杆，所述变幅杆后端与所述前盖板的前端相连；及焊头，安装于所述变幅杆的前端。
一种换能器的组装方法，包括：
将螺杆的一端安装于前盖板上；
在所述螺杆的外周位于所述前盖板的后端的位置套设铁氟龙绝缘套管；
电极片包括电极片本体及设于电极片本体的外缘的引脚，将所述引脚弯折形成至少一个卷曲板，所述卷曲板限定形成有线槽；
将多个压电陶瓷及多个限定有所述线槽的所述电极片依次堆叠套设在所述螺杆的外部位于所述铁氟龙绝缘套管的位置，以构造成压电振子；
将后盖板套设于所述螺杆的外部位于所述压电振子的后端，以将所述压电振子压紧于所述前盖板与所述后盖板之间；及
在每个所述电极片的所述线槽内分别穿设一导线，使所述导线与所述电极片实现电连接，在所述导线与所述电极片的连接处的外表面涂覆绝缘胶。
可选地，上述换能器的组装方法还包括：检测所述螺杆与所述压电振子之间的绝缘电阻是否满足预设条件。
可选地，所述检测所述螺杆与所述压电振子之间的绝缘电阻是否满足预设条件包括：在所述螺杆与所述压电振子之间施加2000V-3000V的电压，若所述螺杆与所述压电振子之间的绝缘电阻大于450MΩ，即满足预设条件。
可选地，上述换能器的组装方法还包括：在所述压电振子的外周壁上涂覆三防漆。
可选地，上述换能器的组装方法还包括：检测所述压电振子的频率、阻抗及电容是否满足预设条件。
可选地，所述在所述压电振子的外周壁涂覆三防漆包括：将所述换能器在55℃-65℃的环境下烘干20min-40min后，在低于50％湿度的环境中，将所述三防漆涂覆于所述压电振子的外周壁。
可选地，上述换能器的组装方法还包括：将所述导线位于所述线槽内的部分焊接于卷曲板。
本申请的换能器、其组装方法及超声波焊接装置，在压电振子与螺杆之间设有铁氟龙绝缘套管，能够确保压电振子与螺杆之间保持彼此绝缘，防止换能器工作时的高压击穿空气及铁氟龙绝缘套管，而避免产生电弧，有效防止漏电；另外，电极片的引脚由至少一个卷曲板通过弯折形成，卷曲板弯折后在其中限定有能供导线穿过的线槽，从而能够保证相邻两个电极片之间保持固定的间距，相对于相关技术中的纯焊接相连，能够避免焊料高温熔融时，导致相邻电极片之间的间距缩小，从而有效降低相邻的电极片之间的打火概率。
附图说明
图1是本申请的换能器的一个实施例的立体视图；
图2是图1所示实施例的纵截面视图；
图3是本申请的换能器的一个实施例的电极片的结构示意图；
图4是本申请的换能器的一个实施例中关于电极片与导线的连接关系的局部示意图；
图5是本申请的超声波焊接装置的一个实施例的立体视图；
图6是本申请的换能器的组装方法的一个实施例的流程示意图。
图中，10、换能器；1、前盖板；2、螺杆；3、压电振子；31、压电陶瓷；32、电极片；321、电极片本体；322、引脚；3221、卷曲板；3222、线槽；323、正极电极片；324、负极电极片；4、后盖板；5、铁氟龙绝缘套管；6、导线；7、螺母；20、变幅杆；30、焊头。
具体实施方式
在本文中所提到的“前端”“后端”分别指的是：在加工过程中，近加工端的为“前端”，远加工端的一端为“后端”，它们是相对的概念，并且因此能够根据其所处于的不同位置和不同的实用状态而改变。所以，不应将这些或其他方位用于理解为限制性用语。
应注意，术语“包括”并不排除其他要素或步骤，并且“一”或“一个”并不排除复数。
此外，还应当指出的是，对于本文的实施例中描述或隐含的任意单个技术特征，或在附图中示出或隐含的任意单个技术特征，仍能够在这些技术特征(或其等同物)之间继续进行组合，从而获得未在本文中直接提及的本申请的其他实施例。
另外还应当理解的是，本文中采用术语“第一”、“第二”等来描述多种信息，但这些信息不应限于这些术语，这些术语仅用来将同一类型的信息彼此区分开。例如，在不脱离本申请范围的情况下，“第一”信息也可以被称为“第二”信息，类似的，“第二”信息也可以被称为“第一”信息。
应当注意的是，在不同的附图中，相同的参考标号表示相同或大致相同的组件。
面对新冠疫情，为了提升口罩和医用防护设备的生产质量，本申请做了如下改进。
如图1-图4所示，本申请实施例的第一方面提供一种换能器10，该换能器10包括：前盖板1、螺杆2、压电振子3及后盖板4，螺杆2的前端与前盖板1相连，压电振子3套设于螺杆2的外部且位于前盖板1的后端，后盖板4套设于螺杆2的外部且位于压电振子3的后端。其中，压电振子3压紧于前盖板1与后盖板4之间，螺杆2的外周相对于压电振子3的位置处设有铁氟龙绝缘套管5，使得螺杆2与压电振子3之间保持彼此绝缘。
基于上述技术方案，由于在螺杆2与压电振子3之间设置有铁氟龙绝缘套管5，铁氟龙材料具有耐高温、机械耐磨以及优良的电绝缘性能，因此在换能器10工作并产生高温的情况下，依然能够保证压电振子3与螺杆2之间保持彼此绝缘，防止工作中压电振子3击穿空气及铁氟龙绝缘套管5，而导致螺杆2产生电弧漏电；当该换能器10应用于超声波焊接装置中时，能够进一步防止焊头漏电，进而提升口罩和医用防护设备的生产质量。
示例性地，如图2所示，本实施例中的螺杆2的后端穿过后盖板4的后端面，并在螺杆2的后端面上锁紧有螺母7，拧紧螺母7能够压紧压电振子3。作为可替换方案，可将螺杆2的后端构造成螺母状，即螺杆2为螺钉结构，直接拧紧螺杆2的后端即可压紧压电振子3，此具体实施方式未在附图中具体示出。
为了进一步保证压电振子3与螺杆2之间良好的绝缘性能，铁氟龙绝缘套管5沿轴向的长度大于每个压电振子3沿轴向的长度；在一实施例中，铁氟龙套管5从前盖板1的后端面开始沿轴向向后延伸，并延伸至超过压电振子3的总高度。
本实施例中，铁氟龙绝缘套管5的厚度为0.5㎜-1㎜，能够保证较好的绝缘性能，且便于安装；在一实施例中，铁氟龙绝缘套管5的厚度约为0.75㎜。
复参阅附图1及图2所示，压电振子3包括以叠堆构造布置的多个压电陶瓷31和多个电极片32，其中每个电极片32设置为分别导通每个压电陶瓷31；每个电极片32上均连接有导线6(参阅图4所示)，导线6与电极片32之间电连接，导线6与电极片32的连接位置的外表面涂覆有绝缘胶(附图中未具体示出)，绝缘胶设置为将导线6和电极片32与外界隔离实现绝缘；在一实施例中，导通压电陶瓷31的正电极面的电极片32为正极电极片323，导通压电陶瓷31的负电极面的电极片32为负极电极片324，通过在导线6与电极片32的连接位置的外表面设置绝缘胶能够有效降低相邻的正极电极片323与负极电极片324之间的打火概率。
本实施例中，相邻两个压电陶瓷31相向的一面的表面极性相同，从而通过一个电极片32能够导通相邻两个压电陶瓷31的正电极面或者负电极面。在一实 施例中，压电振子3包括四个压电陶瓷31及四个电极片32，四个电极片32从前至后依次为：正极电极片323、负极电极片324、正极电极片323及负极电极片324。
相关技术中的换能器中，通常在连接导线6之前，在相邻的两个电极片32之间预留了合理的间距，但是在焊接导线时，由于焊料(例如锡焊)熔融后在轴向延伸预设的宽度，从而导致相邻两个电极片32之间的间距会减小，因此会增大正极电极片323与负极电极片324之间的打火概率。
为了克服此技术问题，本实施例中，请参阅图3和图4，电极片32包括电极片本体321及引脚322，电极片本体321套设于螺杆2的外部，引脚322设于电极片本体321的外缘，引脚322包括至少一个卷曲板3221，在安装过程中利用尖嘴钳将卷曲板3221进行弯折后形成半弧形，从而在卷曲板3221之间预留出线槽3222，导线6的一端穿设于线槽3222内，具体可参阅附图4所示。通过将卷曲板3221弯曲形成线槽3222，并将导线6穿设于线槽3222内，因此，相邻两个电极片32之间的间距是固定的，不会随着后续的焊锡工序而导致间距减小，能够避免焊料高温熔融后导致的间距减小的问题，能够有效保证相邻两个电极片32之间的间距，降低打火概率。
本实施例中，引脚322包括至少两个并排设置的卷曲板3221，为了使得连接更加可靠，相邻两个卷曲板3221朝向相反的方向弯折，每个卷曲板3221的线槽3222对应连通；附图3及图4中仅示出了引脚322包括三个卷曲板3221的具体实施方式，且将两侧的卷曲板3221朝向内侧弯折，中间的卷曲板3222朝向外侧弯折。
在一实施例中，同样可以将每个卷曲板3221朝向相同的方向弯折。
在一实施例中，为了加固导线6，导线6位于线槽3222内的部分与卷曲板3221相焊接；由于线槽形成的空间较小，因此仅需要采用少量的焊料即可，少量焊料熔融后容纳于线槽3221内，不仅不会由于焊接导致相邻的电极片32之间的间距减小，而且焊料将导线和电极片紧密连接，可以进一步保证导线与电极片之间的导电性能。示例性地，本实施例中的导线6与电极片32之间采用锡焊相连。
本申请实施例的还提出了一种超声波焊接装置，具体如图5所示，该超声波焊接装置包括变幅杆20、焊头30及如上述的换能器10，变幅杆20的后端与前盖板1的前端相连，焊头30安装于变幅杆20的前端。
本实施例中的超声波焊接装置，由于包括上述的换能器，因此具有上述换能器的全部有益效果，在此不作赘述。
本申请实施例的第三方面提出一种换能器的组装方法，具体如图6所示，包 括：
S1、将螺杆的一端安装于前盖板上；
S2、在螺杆的外周位于前盖板的后端的位置套设铁氟龙绝缘套管；
S3、电极片包括电极片本体及设于电极片本体的外缘的引脚，将引脚弯折形成至少一个卷曲板，卷曲板限定形成有线槽；
S4、将多个压电陶瓷及多个电极片依次堆叠套设在螺杆的外部位于铁氟龙绝缘套管的位置，以构造成压电振子；
S5、将后盖板套设于螺杆的外部位于所述压电振子的后端，以将所述压电振子压紧于所述前盖板与所述后盖板之间；
S6、在每个所述电极片的线槽内分别穿设一导线，使所述导线与所述电极片实现电连接，在导线与电极片的连接处的外表面涂覆绝缘胶。
基于上述技术方案，由于在压电振子与螺杆之间设置铁氟龙绝缘套管，能够使得换能器在工作过程中，压电振子与螺杆之间保持良好的绝缘，从而防止漏电；另外，由于将电极片的引脚设置成由卷曲板弯折的形式，通过将导线穿设在卷曲板弯折限定所形成的线槽内，实现导线与电极片之间的电连接，并在导线与电极片的连接处的外表面涂覆绝缘胶，相对于相关技术中的纯焊接相连，由于相邻两个电极片之间的间距是固定的，不会随着后续的焊锡工序而导致间距减小，能够避免焊料高温熔融后导致的间距减小的问题，能够有效降低打火概率。
本实施例中的换能器的组装方法还包括步骤：检测螺杆与压电振子之间的绝缘电阻是否满足预设条件。
当螺杆与压电振子之间的绝缘电阻满足预设条件时，才能够保证换能器的绝缘性能，有效防止漏电。
在一实施例中，通过以下方法来检测螺杆与压电振子之间的绝缘电阻是否满足预设条件：在螺杆与压电振子之间施加2000V-3000V的电压，若螺杆与压电振子之间的绝缘电阻大于450MΩ，即满足预设条件。在一实施例中，根据换能器的实际工况，在检测绝缘电阻时，在螺杆与压电振子之间施加2500V的电压，若螺杆与压电振子之间的绝缘电阻大于500MΩ则表明达到绝缘要求。
另外，为了降低换能器在高湿度环境工作时高压打火的概率，还包括步骤S7，步骤S7为在压电振子的外周壁上涂覆三防漆，三防漆主要起到隔离作用。
具体通过以下方法涂覆三防漆：将换能器在55℃-65℃的环境下烘干 20min-40min后，在低于50％湿度的环境中，将三防漆涂覆于压电振子的外周壁。在一实施例中，将换能器在60℃的温度下烘干30min。
在一实施例中，为了加固每个导线，电极片上连接导线还包括：将导线位于线槽内的部分焊接于卷曲板。由于线槽形成的空间较小，因此仅需要采用少量的焊料即可，少量焊料熔融后容纳于线槽3221内，不仅不会由于焊接导致相邻的电极片32之间的间距减小，而且焊料将导线和电极片紧密连接，可以进一步保证导线与电极片之间的导电性能。在其他实施例中，采用锡焊焊接导线与电极片。
综上所述，本实施例中的换能器、其组装方法及超声波焊接装置，在压电振子与螺杆之间设有铁氟龙绝缘套管，能够确保压电振子与螺杆之间保持彼此绝缘，防止换能器工作时的高压击穿空气及铁氟龙绝缘套管，而避免产生电弧，有效防止漏电；另外，由于将电极片的引脚设置成由卷曲板弯折的形式，通过将导线穿设在卷曲板弯折限定所形成的线槽内，实现导线与电极片之间的电连接，相对于相关技术中的纯焊接相连，由于相邻两个电极片32之间的间距是固定的，不会随着后续的焊锡工序而导致间距减小，能够避免焊料高温熔融后导致的间距减小的问题，能够有效降低打火概率。

Claims (13)

  1. 一种换能器，包括：
    前盖板；
    螺杆，所述螺杆前端与所述前盖板相连；
    压电振子，套设于所述螺杆的外部且位于所述前盖板的后端；
    后盖板，套设于所述螺杆的外部且位于所述压电振子的后端；
    其中，所述压电振子压紧于所述前盖板与所述后盖板之间，所述螺杆的外周相对于所述压电振子的位置处设有铁氟龙绝缘套管，使得所述螺杆与所述压电振子之间保持绝缘；
    所述压电振子包括以叠堆构造布置的多个压电陶瓷和多个电极片，每个所述电极片上均连接有导线，所述电极片包括：
    电极片本体，套设于所述螺杆的外部；及
    引脚，设于所述电极片本体的外缘，所述引脚包括至少一个卷曲板，所述卷曲板通过弯折限定形成有线槽；
    其中，所述导线的一端穿设于所述线槽内，与所述电极片电连接，每一所述导线与所述电极片的连接位置的外表面均涂覆有绝缘胶。
  2. 根据权利要求1所述的换能器，其中，所述铁氟龙绝缘套管沿轴向的长度大于所述压电振子沿轴向的长度。
  3. 根据权利要求1所述的换能器，其中，所述铁氟龙绝缘套管的厚度为0.5㎜-1㎜。
  4. 根据权利要求1所述的换能器，其中，所述引脚包括至少两个并排设置的所述卷曲板，相邻两个所述卷曲板朝向相反的方向弯折；每一所述卷曲板的线槽对应连通。
  5. 根据权利要求1-4中任一项所述的换能器，其中，所述导线位于所述线槽内的部分与所述卷曲板相焊接。
  6. 一种超声波焊接装置，包括：
    如权利要求1-5中任一项所述的换能器；
    变幅杆，所述变幅杆后端与所述前盖板的前端相连；及
    焊头，安装于所述变幅杆的前端。
  7. 一种换能器的组装方法，包括：
    将螺杆的一端安装于前盖板上；
    在所述螺杆的外周位于所述前盖板的后端的位置套设铁氟龙绝缘套管；
    电极片包括电极片本体及设于电极片本体的外缘的引脚，将所述引脚弯折形成至少一个卷曲板，所述卷曲板限定形成有线槽；
    将多个压电陶瓷及多个限定有所述线槽的所述电极片依次堆叠套设在所述螺杆的外部位于所述铁氟龙绝缘套管的位置，以构造成压电振子；
    将后盖板套设于所述螺杆的外部位于所述压电振子的后端，以将所述压电振子压紧于所述前盖板与所述后盖板之间；及
    在每一所述电极片的所述线槽内分别穿设一导线，使所述导线与所述电极片实现电连接，在所述导线与所述电极片的连接处的外表面涂覆绝缘胶。
  8. 根据权利要求7所述的换能器的组装方法，还包括：检测所述螺杆与所述压电振子之间的绝缘电阻是否满足预设条件。
  9. 根据权利要求8所述的换能器的组装方法，其中，所述检测螺杆与所述压电振子之间的绝缘电阻是否满足预设条件包括：在所述螺杆与所述压电振子之间施加2000V-3000V的电压，若所述螺杆与所述压电振子之间的绝缘电阻大于450MΩ，即满足预设条件。
  10. 根据权利要求7所述的换能器的组装方法，还包括：在所述压电振子的外周壁上涂覆三防漆。
  11. 根据权利要求7所述的换能器的组装方法，还包括：检测所述压电振子的频率、阻抗及电容是否满足预设条件。
  12. 根据权利要求10所述的换能器的组装方法，其中，所述在压电振子的外周壁涂覆三防漆包括：将所述换能器在55℃-65℃的环境下烘干20min-40min后，在低于50％湿度的环境中，将所述三防漆涂覆于所述压电振子的外周壁。
  13. 根据权利要求7-12中任一项所述的换能器的组装方法，还包括：将所述导线位于所述线槽内的部分焊接于所述卷曲板。
PCT/CN2020/139977 2020-05-18 2020-12-28 换能器、其组装方法及超声波焊接装置 WO2021232795A1 (zh)

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