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CN101898419B - 塑料激光焊接方法 - Google Patents

塑料激光焊接方法 Download PDF

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Publication number
CN101898419B
CN101898419B CN2010101422144A CN201010142214A CN101898419B CN 101898419 B CN101898419 B CN 101898419B CN 2010101422144 A CN2010101422144 A CN 2010101422144A CN 201010142214 A CN201010142214 A CN 201010142214A CN 101898419 B CN101898419 B CN 101898419B
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China
Prior art keywords
workpiece
welding
laser
welded
plastic
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CN101898419A (zh
Inventor
高云峰
朱宝华
胡学安
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Han s Laser Technology Industry Group Co Ltd
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Shenzhen Hans Laser Technology Co Ltd
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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
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/124—Tongue and groove 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
    • 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
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission 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
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1654—Laser beams characterised by the way of heating the interface scanning 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
    • 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
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1677—Laser beams making use of an absorber or impact modifier
    • B29C65/1683—Laser beams making use of an absorber or impact modifier coated on the article
    • 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
    • B29C66/534—Joining single elements to open ends of tubular or hollow articles or to the ends of bars
    • B29C66/5346—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat
    • B29C66/53461—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat joining substantially flat covers and/or substantially flat bottoms to open ends of container bodies
    • 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
    • B29C66/65—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 with a relative motion between the article and the welding tool
    • 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
    • B29C66/65—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 with a relative motion between the article and the welding tool
    • B29C66/652—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 with a relative motion between the article and the welding tool moving the welding tool around the fixed article
    • 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
    • B29C66/733—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 optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence
    • B29C66/7332—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 optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being coloured
    • 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
    • B29C66/733—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 optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence
    • B29C66/7336—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 optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being opaque, transparent or translucent to visible light
    • B29C66/73365—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 optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being opaque, transparent or translucent to visible light at least one of the parts to be joined being transparent or translucent to visible light
    • 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
    • B29C66/733—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 optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence
    • B29C66/7336—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 optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being opaque, transparent or translucent to visible light
    • B29C66/73365—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 optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being opaque, transparent or translucent to visible light at least one of the parts to be joined being transparent or translucent to visible light
    • B29C66/73366—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 optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being opaque, transparent or translucent to visible light at least one of the parts to be joined being transparent or translucent to visible light both parts to be joined being transparent or translucent to visible light
    • 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
    • B29C66/812—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 composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/8126—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 composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/81266—Optical properties, e.g. transparency, reflectivity
    • B29C66/81267—Transparent to electromagnetic radiation, e.g. to visible light
    • 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
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9161—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux
    • B29C66/91641—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux the heat or the thermal flux being non-constant over time
    • B29C66/91643—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux the heat or the thermal flux being non-constant over time following a heat-time profile
    • 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
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1603—Laser beams characterised by the type of electromagnetic radiation
    • B29C65/1612—Infrared [IR] radiation, e.g. by infrared lasers
    • B29C65/1616—Near infrared radiation [NIR], e.g. by YAG lasers
    • 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
    • B29C66/812—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 composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/8122—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 composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the composition of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Electromagnetism (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Thermal Sciences (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Laser Beam Processing (AREA)

Abstract

一种塑料激光焊接方法，包括以下步骤：成型出待焊接连接的第一工件与第二工件，并在第一工件与第二工件上分别成型出相互配合凸起及凹槽形成凸凹式接头；将第一工件与第二工件置于工作台上，并通过相互配合的凸凹式接头定位好第一工件与第二工件之间的装配或连接位置；使待焊接工件与焊接激光光束相对移动，使焊接激光光束相对沿待焊接工件的凸凹式接头位置移动并将凸凹式接头熔融焊接连接在一起；上述塑料激光焊接方法，在待相互焊接连接的工件上成型出相互配合的凸凹式接头结构，通过凸凹式接头解决了待焊接连接工件之间的定位问题，减小待焊接连接工件之间装配带来的误差、及错位；使两者之间良好定位，并提高了工件之间的装配效率。

Description

塑料激光焊接方法
【技术领域】
本发明涉及一种焊接技术，特别是涉及一种塑料激光焊接方法。 
【背景技术】
随着石油的大规模开采使用和石油化工工业的高速发展，塑料作为一种工程材料，成本低廉、获取方便(由石油炼化获取的工业产品)、加工成型技术简单快捷、成品重量轻、物理特性优良、能提供各种工程性能，其应用非常广泛，在工业制造和日常生活中的使用都越来越普遍。 
一件塑料成品一般可能将第一工件20与第二工件40置于工作台100上，并通过相互配合的凸凹式接头定位好第一工件20与第二工件40之间的装配或连接位置。 
种材料或部件制成，或产品中某些塑料件部件之间连接，在某些含塑料材料的产品中或塑料制品的加工过程中人们渴望一种更加快速、有效、干净的连接方式将各个塑料部件结合起来。传统通常可使用机械固定件、粘合剂及焊接等工艺进行连接。上述三种接合方式中，以焊接工艺的效果最佳，而且焊接形式多样，可根据不同材料、尺寸、用途而使用不同的焊接工艺。由于材料和设备方面的进步，使激光焊接技术作为一种连接塑料制品的专门方法得到了生产厂家的认可，主要用于连接敏感性塑料制品(含有线路板)、具有复杂几何形状的塑料件以及有严格洁净要求的塑料制品(医药设备)等等。 
塑料激光焊接的基本原理是将两种塑料在一定压力下被夹紧在一起，激光穿过一个制品，然后被另外一个制品吸收，吸收激光能量的制品将光能转化为热能，在塑料的接触面熔化，形成一个焊接区。 
但现有盒装密封结构的塑料制品中，如其中装设电子元器件的盒装密封结构的塑料制品，一般置于上层的盖板为透明的，下层的底板为白色。原有工艺是使用UV胶之类的黏合剂将上下的盖板与底板进行粘接，但是由于粘接后产品外观质量、结合强度等各方面都达不到要求，因此需要需找新的工艺进行取代。 
随之开始尝试摩擦焊、超声波焊等方法进行连接。但由于盒体内部装有电子元器件，如采用摩擦焊、超声波焊等方法可能会对电子元器件造成损伤，同时无法保证盒体的密封防水功能。
而与传统的塑料焊接技术相比，激光焊接塑料技术主要有以下几方面的优点：①能生成精密、牢固和密封(不透气和不漏水)的焊接；②易于控制，具有良好的适应性；③极大地减小了制品的振动应力和热应力；④能够将许多种类不同的材料焊接在一起。 
焊接前需对待焊接工件之间进行准确定位，不然会导致产品焊接位置出现偏移或连接不稳定，且由于工件之间的位置出现偏移会导致焊接时工件的焊接位置相对于激光光束偏位，激光光束损伤到盒体中的电子元器件，甚至造成焊接后的产品不合要求。 
由于传统焊接的接头形式一般都为平面接触，装配或连接过程中定位困难，在焊接过程中就会出现偏位，引起一系列问题。 
另由于上述一类的盒装密封结构的塑料制品中，相连接的上下材料都为透明材质、或透明与白色材质，底层白色材质或透明材质对激光的吸收率很低，熔化效率很不理想，无法满足激光焊接中对底层材料吸收激光的要求。 
【发明内容】
基于此，有必要提供一种在塑料焊接过程中对待焊接工件准确定位的塑料激光焊接方法。 
一种塑料激光焊接方法，包括以下步骤： 
成型出待焊接连接的第一工件与第二工件，并在第一工件与第二工件上分别成型出相互配合凸起及凹槽形成凸凹式接头； 
将第一工件与第二工件置于工作台上，并通过相互配合的凸凹式接头定位好第一工件与第二工件之间的装配或连接位置； 
使待焊接工件与焊接激光光束相对移动，使焊接激光光束相对沿待焊接工件的凸凹式接头位置移动并将凸凹式接头熔融焊接连接在一起，所述焊接激光光束于待焊接部位的激光光斑直径不小于所述凸凹式接头中的凹槽宽度。 
在优选的实施例中，所述第一工件为透明材质制成，所述第二工件为透明 材质或浅色材质制成。 
在优选的实施例中，所述凸凹式接头于焊接激光光束的出射方向相对上下位置设置，所述凸凹式接头的凹槽底面为吸收激光部位。 
在优选的实施例中，所述第一工件与第二工件装配或连接前，于第二工件的凹槽底面上涂覆激光吸收剂；所述凸凸起高度不低于所述凹槽深度设置。 
在优选的实施例中，所述激光吸收剂为对可见光透明的染料。 
在优选的实施例中，所述待焊接连接的第一工件与第二工件置于工作台时通过夹具定位夹紧，所述第一工件与第二工件于焊接激光光束的出射方向相对上下位置设置。 
在优选的实施例中，所述夹具包括覆盖在所述第一工件上的压板、设置在第二工件底部并与第二工件外形相匹配的底部支撑块及提供压力给所述压板的动力装置，所述压板为透明板。 
在优选的实施例中，所述激光光束提供的能量由能量密度决定，能量密度由以下公式确定：能量密度＝(焊接功率×焊接速度)/光斑直径，所述光斑直径通过调节焦点位置进行调节。 
在优选的实施例中，所述待焊接工件与激光光束之间的相对运动通过工作台运动带动待测工件运动而相对出射的激光光束运动，所述激光器的功率根据工作台的运动速度进行调节并调节补偿工作台加速或减速过程中的能量变化。 
上述塑料激光焊接方法，在待相互焊接连接的工件上成型出相互配合的凸凹式接头结构，通过凸凹式接头解决了待焊接连接工件之间的定位问题，减小待焊接连接工件之间装配带来的误差、及错位；使两者之间良好定位，并提高了工件之间的装配效率。 
【附图说明】
图1为本发明一实施例的激光焊接机的整体结构示意图； 
图2为本发明一实施例的待焊接工件的结构示意图； 
图3为本发明一实施例的待焊接工件与夹具结合的结构示意图； 
图4为本发明一实施例的工作台速度与相应的能量补偿示意图。 
下面结合附图对本发明一实施例进行具体说明。 
【具体实施方式】
品的振动应力和热应力；④能够将许多种类不同的材料焊接在一起。 
焊接前需对待焊接工件之间进行准确定位，不然会导[0031] 本发明一实施例的塑料激光焊接方法，包括以下步骤：成型出待焊接连接的第一工件20与第二工件40，并在第一工件20与第二工件40上分别成型出相互配合凸起及凹槽形成凸凹式接头(如图2所示)。 
使待焊接工件与焊接激光光束相对移动，使焊接激光光束相对沿待焊接工件的凸凹式接头位置移动并将凸凹式接头熔融焊接连接在一起。 
另待焊接工件于焊接连接前，在工作台100上设置夹具以定位夹紧待焊接工件。夹具同时提供一定的压力给待焊接工件，以使第一工件20与第二工件40更好的接触。 
第一工件20与第二工件40装配前先涂覆激光吸收剂于凸凹式接头的凹槽底面上。 
如图1至3所示，第一工件20与第二工件40于激光光束的出射方向上相对上下位置设置。凸凹式接头于激光光束的出射方向相对上下设置，包括凸起200及凹槽400。凸起200突设于第一工件20上的与第二工件40相接触的一面。凹槽400设置在第二工件40上并与凸起200对应配合设置。凹槽400的凹槽底面为吸收激光部位。第一工件20及第二工件40设置的凸凹式接头提供了相互连接工件之间良好定位，并提高了两个工件之间的装配效率。 
特别当第一工件20由透明塑料材质制成，第二工件40由透明塑料材质制成或由浅色塑料材质如白色塑料材质制成。 
相对置于下层的第二工件40由于为透明或白色等浅色部件无法吸收或不能很好吸收激光能量，待焊接连接部位的熔化效率不理想，无法满足激光焊接中对下层部件吸收激光的要求。因此需要在相对置于下层的第二工件中加入吸收激光的物质，如炭黑之类。但是加入炭黑之类的物质后无可避免的会改变下层的第二工件40的颜色，无法满足要求。 
故本实施例中的，采用对可见光透明的激光吸收剂。其中可采用英国焊接学会研制的一种对可见光透明的染料，用这种染料做激光吸收剂，可以得到透明的塑料焊缝。该染料为液体成分，焊接前将其涂覆在相对置于下层的第二工件40上需焊接的部位。 
如果是第一工件20与第二工件40为平面接触方式，则涂覆的焊接位置无法准确保证。且由于第一工件20与第二工件40之间是平面接触则涂覆工序中可能导致第一工件20与第二工件40之间的相互之间的相对位置偏移，造成焊接连接位移位。同时由于是平面接触，在平面上涂覆液体状态的激光吸收剂会因采用的涂覆方式不同，涂覆的均匀度也无法保证。 
本实施例中，将传统的第一工件与第二工件之间的平面接触焊接结构优化为凸凹式接头结构。第一工件20与第二工件40通过注塑模注塑成型，并分别在第一工件20及第二工件40上成型出凸起200及凹槽400。激光吸收剂通过专用的点胶设备(如Needle Tip点胶机)或涂覆笔手工涂覆在底部的第二工件40的凹槽400中，并可避免污染工件上的其他部位。优选的，第一工件20的凸起200高度不能小于第二工件40的凹槽400的深度，即凸起200高度设置为等于或略大于第二工件40的凹槽400的深度。 
第一工件20与第二工件40设置的相互配合的凸凹式接头结构，一方面可以解决工件之间的定位问题，减小装配带来的误差和错位；同时有助于激光吸收染料的涂覆，染料通过点胶设备或手工涂覆在置于下层的第二工件40的凹槽400中，避免污染待焊接工件的其他部位。 
同时激光器通过激光焊接头发射出的激光光斑设置成等于或大于凹槽400宽度。本实施例中，为了获得更好的焊接效果，将激光光斑调节为略大于凹槽400宽度的激光光斑，并选择匹配的焊接功率和速度，即可实现无痕迹的焊接。 
待焊接工件上连接设置有将待焊接工件定位在工作台上的夹具，包括设置在底部与第二工件40外形相匹配的底部支撑块60、相对置于第一工件20上部的压板80及与压板80连接的动力装置。动力装置本实施例中采用气缸90，当然也可采用电机或其他动力传动装置。 
底部支撑块60本实施例中为金属模具，支撑待焊接工件，与第二工件40 的外形相匹配并定位、固定第二工件40。 
压板80设置在第一工件20上方，由气缸90带动上下移动而压制在第一工件20上。压板80为透明板，如可采用透明材质PC或PMMA等制成，可90％以上透过激光。优选的，压板的厚度设置为约为8mm～10mm。压板80太厚，激光透过率会受到影响，而太薄则无法保证其刚性，对待焊接工件施加的压力均匀性较差。气缸90可根据需要对实施的压力可以进行调节，以适应不同材质、强度制品的装夹。压板80与底部支撑块60配合夹紧待焊接工件。 
且保证第一工件20的凸起200高度不能小于第二工件40的凹槽的400深度，以保证通过气缸90带动的压板80覆盖压制在第一工件20上对第一工件20施加压力，实现第一工件20与第二工件40之间的待焊接面的良好贴合，进而保证焊接时不会出现因工件之间贴合不好出现的烧焦、气泡等焊接缺陷，得到无缺陷的焊缝。 
如图1所示，本实施例中，承载待焊接工件的工作台选用三维工作台104。三维工作台包括带动待焊接工件作X、Y方向的运动的水平工作台、及可带动激光器的光纤准直焦头作Z方向运动的垂直工作台。本实施例的三维工作台104可焊接点、直线、圆、方形或由直线、圆弧等组成的任意平面图形的工件。 
由于塑料本身有其自身的融化温度、分解温度的限制，塑料焊接过程中需要提供的能量使塑料焊接部位处于融化温度的区间内，又不能达到其分解温度导致其失效。 
激光器105提供的激光光束所能提供能量大小由激光提供的能量密度来决定：能量密度J/mm2＝(焊接功率W×焊接速度mm/s)/光斑直径mm。 
光斑直径大小可通过改变激光器105的焦点位置进行改变，以获得需要的光斑尺寸。 
另夹具压力是外部因素，压力的大小会影响待焊接工件之间的导热条件和焊接效果。夹具提供给待焊接工件的夹紧力在焊接过程中根据需要进行调试。 
如图1及图5所示，待焊接工件的平面移动由水平工作台在X、Y方向的运动实现。激光器在工作过程中发射出的激光能量为连续能量。激光器提供的激光能量根据水平工作台的运动速度进行调节。 
如图5所示，水平工作台在焊接开始及结束位置在X/Y平面上的运行设置为渐进渐出。焊接过程中包括上升段、设定值工作段、拐角段、设定值工作段、及下降段。 
焊接开始阶段为上升段，水平工作台在X/Y平面上的运动属于加速过程，此时激光器提供的能量也与水平工作台在X/Y平面上的运动速度进行相适应调节，能量逐渐升高至设定值。焊接结束段或焊接过程中拐角段，水平工作台会减速，此时能量会降低到设定数值，以此来保证能量和速度的协调。水平工作台在上升阶段、拐角段及下降阶段的加速度根据需要进行设定，且可根据需要设定为任意数值。上升段的加速度、下降段的加速度、工作段的速度设定值及工作段的激光器105的功率设定值、拐角段的速度及激光器的功率下降设定值都根据实际焊接需要进行设置。 
整个焊接过程由控制装置109进行控制，并设置有监控器107对整个焊接过程进行监控。 
根据塑料对激光的透射与反射特性，同时结合不同激光器的光束特点，本实施例中激光器选用半导体激光器。如图4所示，半导体激光器与Nd:YAG激光器的光束对比示意图。半导体激光器光束为平顶波光束，焊缝一致性好。而Nd:YAG激光器或光纤激光器光束为高斯光束，峰值较高，容易损伤工件，焊缝一致性较差。且从经济上来说，半导体激光器的电光转换效率及运行成本较Nd:YAG激光器也具有很大的优势。 
本实施例中，优选的，半导体激光器选用波长为980nm的半导体连续激光器，透明塑料对此波长的激光透过率可达90％左右。并选用最大功率可达120W的半导体连续激光器，焊接起始段上升时间及焊接结束下降段时间均可根据焊接速度的需要进行调节，以消除工作台加速或减速造成的能量变化。 
本实施例中，第一工件20与第二工件40的相配合的凸凹式接头结构需考虑两工件之间结合面尺寸，不适合于结合面尺寸过小的工件或制品。 
本实施例中，使用半导体激光器进行制品的焊接，可以获得优于粘接及传统焊接方法所得到的制品，外观一致性、结合的强度及制品的密防水封性能都得到了很好的提高；同时大幅提高了制品的生产效率，为制品生产的半自动化 和自动化创造了有利的条件。 
创新性地采用凹凸式结合面，提高了工件或制品间的装配速度，解决了工件之间的装配定位问题，同时为激光吸收染料的涂覆提供了良好的通道，提高了制品的生产效率和质量水平。 
以上所述实施例仅表达了本发明的几种实施方式，其描述较为具体和详细，但并不能因此而理解为对本发明专利范围的限制。应当指出的是，对于本领域的普通技术人员来说，在不脱离本发明构思的前提下，还可以做出若干变形和改进，这些都属于本发明的保护范围。因此，本发明专利的保护范围应以所附权利要求为准。 

Claims (7)

1.一种塑料激光焊接方法，其特征在于，包括以下步骤：
成型出待焊接连接的第一工件与第二工件，并在第一工件与第二工件上分别成型出相互配合凸起及凹槽形成凸凹式接头；
将第一工件与第二工件置于工作台上，并通过相互配合的凸凹式接头定位好第一工件与第二工件之间的装配或连接位置；
使待焊接工件与焊接激光光束相对移动，使焊接激光光束相对沿待焊接工件的凸凹式接头位置移动并将凸凹式接头熔融焊接连接在一起，所述焊接激光光束于待焊接部位的激光光斑直径不小于所述凸凹式接头中的凹槽宽度；
其中，所述待焊接工件与激光光束之间的相对运动通过工作台运动带动待测工件运动而相对出射的激光光束运动，激光器的功率根据工作台的运动速度进行调节并调节补偿工作台加速或减速过程中的能量变化，待焊接工件的平面移动由水平工作台在X、Y方向的运动实现，水平工作台在焊接开始及结束位置在X/Y平面上的运行设置为渐进渐出，焊接过程中包括上升段、设定值工作段、拐角段、设定值工作段、及下降段；
所述激光器在工作过程中发射出的激光能量为连续能量，激光器提供的激光能量的功率根据水平工作台的运动速度进行调节，焊接开始阶段为上升段，水平工作台在X/Y平面上的运动属于加速过程，功率逐渐升高至设定值，达到设定值工作段，焊接至拐角处，水平工作台减速，功率逐渐减小，进入拐角段，经过拐角后，水平工作台加速，功率逐渐增大，进入设定值工作段，焊接结束时，水平工作台会减速，此时功率会降低进入下降段，以此来保证能量和速度的协调。
2.根据权利要求1所述的塑料激光焊接方法，其特征在于，所述第一工件为透明材质制成，所述第二工件为透明材质或浅色材质制成。
3.根据权利要求1所述的塑料激光焊接方法，其特征在于，所述凸凹式接头于焊接激光光束的出射方向相对上下位置设置，所述凸凹式接头的凹槽底面为吸收激光部位。
4.根据权利要求1所述的塑料激光焊接方法，其特征在于，所述第一工件与第二工件装配或连接前，于第二工件的凹槽底面上涂覆激光吸收剂；所述凸凸起高度不低于所述凹槽深度设置。
5.根据权利要求4所述的塑料激光焊接方法，其特征在于，所述激光吸收剂为对可见光透明的染料。
6.根据权利要求1所述的塑料激光焊接方法，其特征在于，所述待焊接连接的第一工件与第二工件置于工作台时通过夹具定位夹紧，所述第一工件与第二工件于焊接激光光束的出射方向相对上下位置设置。
7.根据权利要求6所述的塑料激光焊接方法，其特征在于，所述夹具包括覆盖在所述第一工件上的压板、设置在第二工件底部并与第二工件外形相匹配的底部支撑块及提供压力给所述压板的动力装置，所述压板为透明板。
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