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CN102107530A - 一种采用金属激光焊接机焊接塑料的新方法 - Google Patents

一种采用金属激光焊接机焊接塑料的新方法 Download PDF

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CN102107530A
CN102107530A CN2010106147726A CN201010614772A CN102107530A CN 102107530 A CN102107530 A CN 102107530A CN 2010106147726 A CN2010106147726 A CN 2010106147726A CN 201010614772 A CN201010614772 A CN 201010614772A CN 102107530 A CN102107530 A CN 102107530A
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welding
laser
welding machine
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infrared laser
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梁昆
易光纯
雷江红
彭春阳
吴中政
杨军
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Dongguan Trump Opto Electronic Co ltd
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    • 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
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    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
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    • 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
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
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    • 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
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    • B29C65/1687—Laser beams making use of light guides
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • 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
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Abstract

本发明公开了一种采用金属激光焊接机焊接塑料的新方法，步骤如下：a）采用计算机控制专用板卡，输出一定频率、波长为800-1064nm的近红外线激光；b）把待焊接的两件塑料部件夹紧在一起，让近红外线激光以偏离焦点的方式透射过第一个部件，然后被第二个部件吸收所，所吸收的近红外线激光化为热能，将两个部件的接触表面熔化，形成焊接区；本方法能生成精密、牢固和密封的焊接，而且树脂降解少、产生的碎屑少，制品的表面能够在焊缝周围严密地连接在一起，只需要很低的频率就可以实现高速焊接，是一般塑料焊接效率的三倍。

Description

一种采用金属激光焊接机焊接塑料的新方法
 
技术领域
本发明属于激光焊接技术领域，具体涉及一种采用金属激光焊接机焊接塑料的新方法。
背景技术
传统的塑料焊接是采用加热的方式实现，热影响区大，表面会有变形，从而影响外观。而且焊接制品的振动应力和热应力很大，这意味着制品或者装置内部组件的老化速度很快，大大缩短了产品的使用寿命。
迄今为止还未有广泛的研究，应用金属激光焊接机来焊接不同材料的塑料部件。
发明内容
本发明的目的在于提供一种利用激光焊接机把两件塑料部件焊接在一起的方法。
本发明解决其技术问题所采用的技术方案是：一种采用金属激光焊接机焊接塑料的新方法，步骤如下：a）、采用计算机控制专用板卡，输出一定频率、波长为800-1064nm的近红外线激光；b）、把待焊接的两件塑料部件夹紧在一起，让近红外线激光以偏离焦点的方式透射过第一个部件，然后被第二个部件吸收所，所吸收的近红外线激光化为热能，将两个部件的接触表面熔化，形成焊接区。
进一步，所述步骤b）中焦点偏离的距离为50-90mm，光斑直径为3-5mm 。
更近一步，所述的焊接机为半导体激光焊接机、光纤激光焊接机或端泵激光焊接机。
再进一步，所述的焊接工艺参数如下：电流为150-180A，脉宽为8-10ms，速度为2700mm/s，频率为2Hz。
本发明的有益效果是：
（1） 能生成精密、牢固和密封（不透气和不漏水）的焊接，而且树脂降解少、产生的碎屑少，制品的表面能够在焊缝周围严密地连接在一起；
（2） 易于控制，具有良好的适应性，可焊接尺寸小或外形结构复杂的工件；
（3） 极大地减小了制品的振动应力和热应力，比采用其它连接方式所产生的振动应力和热应力小得多；
（4） 能够将许多种类不同的材料焊接在一起；
（5） 由于偏离焦距焊接，焊接光斑大，只需要很低的频率就可以实现高速焊接，是一般塑料焊接效率的三倍。
附图说明
图1是本发明正焦距焊接时的原理图；
图2是本发明负焦距焊接时的原理图。
具体实施方式
下面结合实施例对本发明作进一步详细说明。
一种采用金属激光焊接机焊接塑料的新方法，这种焊接方法能够造出超过原材料强度的焊接缝，步骤如下：
a）、选用半导体激光焊接机、光纤激光焊接机或端泵激光焊接机，采用计算机控制专用板卡，输出一定频率、波长为800-1064nm的近红外线激光；
b）、把待焊接的两件塑料部件夹紧在一起，让近红外线激光以偏离焦点的方式透射过第一个部件，其中焦点偏离的距离为50-90mm，光斑直径为3-5mm，激光被第二个部件吸收所，所吸收的近红外线激光化为热能，将两个部件的接触表面熔化，形成焊接区，所述的焊接工艺参数如下：电流为150-180A，脉宽为8-10ms，速度为2700mm/s，频率为2Hz。
如图1、图2所示，激光器1产生的激光3经聚焦透镜2投射到两块塑料上，穿过透明塑料5后在非透明塑料6上形成光斑4，最终聚焦在焦平面7上。
由于焊接机激光发散角度小，光学模式好将，通常在焦点位置打标时其光斑大小为0.06mm，这样对精密塑料焊接提供了可行性依据，打标是高速振镜摆动完成光学坐标点位置的定位标刻，当采用塑料元件作为打标元件时，由于塑料对激光波长的吸收，这样在激光扫描的线条上会产生加工热熔痕迹，利用这一特性，利用打标的原理完成打标的轨迹实现塑料焊接的功能。
焊接焦距的选择，通常焊接工件时处在激光偏离焦点4mm内，长距离的偏焦是用在焊接成型后起到整平美观的作用。但如果偏离焦点30-50mm的位置上进行塑料焊接时，就能达到塑料焊接的牢固。用该设备焊接塑料时必须离焦焊，原因是正焦点焊接时由于功率密度高，塑料对激光波长的吸收一般在810--980nm，而采用1064nm波长时，塑料对激光的吸收就不是很好，这样在正焦点焊接时很容易将塑料的上表面烧伤，达不到焊接要求，试验证明在焦点位置偏移不远的位置上进行焊接，其上表面透明塑料会有严重的烧伤，而且会出现不规则的打孔点。两块塑料之间没有任何的连接强度。
本发明的焊接方法具有如下的有益效果：
（1） 能生成精密、牢固和密封（不透气和不漏水）的焊接，而且树脂降解少、产生的碎屑少，制品的表面能够在焊缝周围严密地连接在一起，没有残渣的优点使它比较适合于国家食品药品监督管理局管制的医药制品及电子传感器等。 
（2） 易于控制，具有良好的适应性，可焊接尺寸小或外形结构复杂的工件，这主要是因为激光便于计算机软件控制，
（3） 极大地减小了制品的振动应力和热应力，比采用其它连接方式所产生的振动应力和热应力小得多，这意味着制品或者装置内部组件的老化速度更慢，可应用于极易损坏的制品。
（4） 能够将许多种类不同的材料焊接在一起， 例如能将透过近红外激光的聚碳酸脂（PC）和30%玻纤增强的黑色聚对苯二甲酸丁二脂（PBT）连接在一起，而其它的焊接方法根本不可能将两种在结构、软化点和增强材料等方面如此不同的聚合物连接起来。
（5） 焊接效率高，焊接频率低。由于是高斯光，激光融化、焊接更加平整，激光焊接光斑由于大距离的偏离焦点，光斑大（一般5-10mm)，这样要满足密封焊接要求时，焊接的速度自然就会很快，由于偏离焦距焊接，焊接光斑大，只需要很低的频率就可以实现高速焊接，是一般塑料焊接效率的三倍。
几乎所有的热塑性塑料和热塑性弹性体都可以使用激光焊接技术，常用的焊接材料有 PP、PS、PC、ABS、聚酰胺、PMMA、聚甲醛、PET以及PBT等，而其它的一些工程塑料如聚苯硫醚PPS和液晶聚合物等，由于其具有较低的激光透过率而不太适合使用激光焊接技术，因此常常在底层材料上加入炭黑，以便使其能吸收足够能量，从而满足激光透射焊接的要求。
未填充的或者玻纤增强的聚合材料都可以用于激光焊接，但是过高的玻纤含量会散射发出得IR激光，降低光束通过聚合物的穿透力。
有色塑料也可以用于激光焊接，但是随着颜料或染料含量的增加，激光束的通过塑料的穿透能力会有所下降。
上述实施例仅例示性说明本发明的原理及其功效，以及部分运用的实施例，对于本领域的普通技术人员来说，在不脱离本发明创造构思的前提下，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。

Claims (4)

1.一种采用金属激光焊接机焊接塑料的新方法，其特征在于，步骤如下：
a）、采用计算机控制专用板卡，输出一定频率、波长为800-1064nm的近红外线激光；
b）、把待焊接的两件塑料部件夹紧在一起，让近红外线激光以偏离焦点的方式透射过第一个部件，然后被第二个部件吸收所，所吸收的近红外线激光化为热能，将两个部件的接触表面熔化，形成焊接区。
2.根据权利要求1所述的焊接塑料的新方法，其特征在于，所述步骤b）中焦点偏离的距离为50-90mm，光斑直径为3-5mm 。
3.根据权利要求2所述的焊接塑料的新方法，其特征在于，所述的焊接机为半导体激光焊接机、光纤激光焊接机或端泵激光焊接机。
4.根据权利要求3所述的焊接塑料的新方法，其特征在于，所述的焊接工艺参数如下：电流为150-180A，脉宽为8-10ms，速度为2700mm/s，频率为2Hz。
CN2010106147726A 2010-12-30 2010-12-30 一种采用金属激光焊接机焊接塑料的新方法 Pending CN102107530A (zh)

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CN107405836A (zh) * 2016-02-23 2017-11-28 精电舍电子工业株式会社 激光焊接装置及激光焊接方法
CN109421280A (zh) * 2017-08-24 2019-03-05 上海肇民新材料科技有限公司 一种用于热塑性塑料的激光焊接方法
CN111565883A (zh) * 2018-01-03 2020-08-21 通快激光与系统工程有限公司 用于激光可透过的工件的表面结构化的方法和激光加工机
CN113155167A (zh) * 2021-04-22 2021-07-23 珠海上富电技股份有限公司 一种免注灌封胶密封的超声波传感器
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CN104395059A (zh) * 2012-07-05 2015-03-04 旭化成化学株式会社 焊接方法及焊接体
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CN113155167A (zh) * 2021-04-22 2021-07-23 珠海上富电技股份有限公司 一种免注灌封胶密封的超声波传感器

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