CN111002591A - 一种用于塑件的激光透射焊接方法 - Google Patents
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Abstract
本发明公开了一种用于塑件的激光透射焊接方法，所述为光学透明热塑性塑件，其包括如下步骤：在第二塑件的待焊接部位上直接放置金属吸收剂，或在第二塑件的待焊接部位上开槽后将金属吸收剂放置于槽内；将第一塑件的待焊接部位压住金属吸收剂后搭接在第二塑件的待焊接部位上，并用夹具将第一塑件、第二塑件夹紧；激光器产生的激光光束对第一塑件的待焊接部位进行一次或多次辐射，所述激光光束穿过第一塑件并对准金属吸收剂，在激光光束能量的作用下金属吸收剂附近的塑料熔化，所述第一塑件与第二塑件之间的缝隙熔合，从而将第一塑件与第二塑件焊接起来。本发明能够有效的保持焊接的美观性，提高焊接质量和效率，同时，还能避免塑件烧焦。
Description
技术领域
本发明涉及激光焊接技术领域，尤其涉及的是一种用于塑件的激光透射焊接方法。
背景技术
塑料产品通常由两个或两个以上部件组合而成，将这些部件组装在一起，常用到机械固定、粘合剂连接、热焊接等三种方式。机械固定、粘合剂连接加工程序较为复杂，同时可能产生对人类身体健康有潜在威胁的杂质，在一些诸如医疗、食品行业中是不允许的。摩擦焊（超声焊、振动焊、旋转焊等）、电熔焊、热板焊等多种无须添加外来物质的热焊接是这些领域中塑料产品常用的连接方法，但摩擦焊、电熔焊和热板焊等方法的加工精度较为粗糙，一般适用于低精度的焊接场合。
激光焊接作为相对新的焊接技术，具有诸多的优势：（1）非接触式焊接；（2）光束形状和尺寸可调控，可减小热影响区和焊缝宽度，减少热应力；（3）焊接速度快及效率高；（4）焊缝强度高、无残渣、具有良好外观等。因此激光焊接技术不仅能够满足高精密加工要求，而且能够保证高强度连接要求。
随着激光器成本的下降，激光焊接技术逐渐应用于塑料焊接的领域中。目前市场上的塑料激光焊接设备大都是将波长≤1200nm的近红外激光作为光源，而绝大多数光学透明热塑性塑料本身对近红外激光的吸收较弱（10%，1mm厚样品），一般不能直接焊接。所以在当前的塑料激光透射焊接技术中，为提高塑料对激光的吸收率，人们往往在两光学透明塑料中添加光吸收剂。如图1和2所示，图中1表示上层塑料，2表示下层塑料，3表示光吸收剂，4表示激光光束，5表示焊缝，现有技术中的光学透明塑料激光焊接方法有三个步骤：（1）在下层塑料上表面均匀涂覆粉末状或液态的光吸收剂；（2）使用专门夹持装置夹紧两塑料；（3）使用激光光束进行焊接。焊接时，激光光束透射过上层塑料，被下层塑料上表面涂覆的吸收剂的吸收，转化成热量，热量熔化下层塑料，同时通过热传递作用进入上层塑料，熔化上层塑料，于是两层塑料在激光辐射处熔合、冷却，形成焊缝。
现有技术中的光学透明塑料激光焊接方法存在明显的缺陷：（1）涂覆的光吸收剂通常为碳黑、树脂、金属氧化物、合金粉末、Clearweld等粉末状或液状物质，这些物理性能不稳定的物质易扩散到焊接区域外，对焊接件造成污染，这在一些高清洁度行业中（比如医疗、食品、精密电子等）是不允许的；（2）一些商业化的特殊吸收剂价格较为昂贵，使用这些吸收剂会造成焊接成本增加；（3）一般涂覆工艺为：用溶剂溶解吸收剂，将混合液搅拌均匀再涂覆于塑料表面，等溶剂蒸发干后再进行焊接。整个涂覆工艺过程较为繁琐，时间较长，导致焊接效率降低；（4）目前涂覆工艺大都为人工涂覆，涂覆质量严重依赖于操作者的技术水平，若技术水平差，则易导致因涂覆不均匀而造成的焊接质量不佳；（5）在界面间的吸收剂会阻碍上下层塑料间的分子扩散和缠结，降低了两塑料的结合力；（6）塑料和吸收剂的导热性很差，若吸收剂涂覆不均匀或激光功率不稳定，则易造成塑料局部因能量过高而瞬间烧焦。
因此，现有技术还有待于改进和发展。
发明内容
鉴于上述现有技术的不足，本发明的目的在于提供一种用于塑件的激光透射焊接方法，采用金属吸收剂代替染料作为吸收剂，提高其焊接效率和质量。
本发明的技术方案如下：
一种用于塑件的激光透射焊接方法，用于第一塑件与第二塑件之间的激光焊接，所述第一塑件为光学透明热塑性塑件，其包括如下步骤：
在第二塑件的待焊接部位上直接放置金属吸收剂，或在第二塑件的待焊接部位上开槽后将金属吸收剂放置于槽内；
将第一塑件的待焊接部位压住金属吸收剂后搭接在第二塑件的待焊接部位上，并用夹具将第一塑件、第二塑件夹紧；
激光器产生的激光光束对第一塑件的待焊接部位进行一次或多次辐射，所述激光光束穿过第一塑件并对准金属吸收剂，在激光光束能量的作用下金属吸收剂附近的塑料熔化，所述第一塑件与第二塑件之间的缝隙熔合，从而将第一塑件与第二塑件焊接起来。
优选地，所述在第二塑件的待焊接部位上直接放置金属吸收剂，或在第二塑件的待焊接部位上开槽后将金属吸收剂放置于槽内之前还包括：
用酒精去除第一塑件和第二塑件表面的油渍和污物。
优选地，所述金属吸收剂为金属丝、金属膜或金属片。
优选地，所述金属丝的宽度为0.2-1.0 mm，厚度为0.1-0.5 mm。
优选地，所述金属膜和金属片都设置成带有若干个通孔的长方形、圆形或其它不规则形状。
优选地，所述金属膜和金属片都通过激光切割、化学腐蚀、冲床冲压加工制成。
优选地，所述金属吸收剂都由导热性良好的铁、铝、铜或其合金制造而成。
优选地，所述第二塑件为热塑性塑料。
优选地，所述第一塑件和第二塑件被夹持在两块对激光光束高透且耐高温的石英玻璃板之间，并通过两个带可调气压阀的三杆气缸夹紧。
优选地，所述激光器为连续近红外半导体激光器，所述激光光束的直径或宽度大于金属吸收剂的宽度。
与现有技术相比，本申请实施例主要有以下有益效果：
（1）金属吸收剂的物理性能稳定，不会产生颗粒杂质，不会污染焊接件，保持美观性，可应用于有高清洁度要求的行业；
（2）金属吸收剂可为常见的铁、铝或铜等金属及其合金，来源广泛、价格便宜；
（3）焊接时，操作者直接将金属吸收剂置于焊接部位即可焊接，操作简单、效率较高；
（4）操作者不需要长时间培训即可熟练操作，不存在涂覆不均匀的问题，焊接质量稳定；
（5）焊缝内没有外来的颗粒杂质影响分子扩散和缠结，焊接强度高；
（6）金属吸收剂导热性良好，若发生激光功率瞬间过高，则金属可及时扩散瞬间过多的热量，起缓冲作用，避免塑料烧焦。
附图说明
为了更清楚地说明本申请的方案，下面将对实施例描述中所需要使用的附图作一个简单介绍，显而易见地，下面描述中的附图是本申请的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1是现有技术中的塑料焊接的分解图。
图2是现有技术中的塑料焊接的结构示意图。
图3是本发明中的用于塑件的激光透射焊接方法较佳实施例的分解图。
图4是本发明中的用于塑件的激光透射焊接方法较佳实施例的结构示意图。
图5是本发明中的用于塑件的激光透射焊接方法又一较佳实施例的分解图。
图6是本发明中的用于塑件的激光透射焊接方法又一较佳实施例的结构示意图。
具体实施方式
除非另有定义，本文所使用的所有的技术和科学术语与属于本申请技术领域的技术人员通常理解的含义相同；本文中在申请的说明书中所使用的术语只是为了描述具体的实施例的目的，不是旨在于限制本申请；本申请的说明书和权利要求书及上述附图说明中的术语“包括”和“具有”以及它们的任何变形，意图在于覆盖不排他的包含。本申请的说明书和权利要求书或上述附图中的术语“第一”、“第二”等是用于区别不同对象，而不是用于描述特定顺序。
在本文中提及“实施例”意味着，结合实施例描述的特定特征、结构或特性可以包含在本申请的至少一个实施例中。在说明书中的各个位置出现该短语并不一定均是指相同的实施例，也不是与其它实施例互斥的独立的或备选的实施例。本领域技术人员显式地和隐式地理解的是，本文所描述的实施例可以与其它实施例相结合。
如图3至6所示，图中6表示第一塑件，7表示第二塑件，8表示金属吸收剂，9表示激光光束，10表示焊缝。结合附图具体说明一种用于塑件的激光透射焊接方法，用于第一塑件与第二塑件之间的激光焊接，所述第一塑件为光学透明热塑性塑件，其包括如下步骤：
S100、在第二塑件的待焊接部位上直接放置金属吸收剂，或在第二塑件的待焊接部位上开槽后将金属吸收剂放置于槽内；
S200、将第一塑件的待焊接部位压住金属吸收剂后搭接在第二塑件的待焊接部位上，并用夹具将第一塑件、第二塑件夹紧；
S300、激光器产生的激光光束对第一塑件的待焊接部位进行一次或多次辐射，所述激光光束穿过第一塑件并对准金属吸收剂，在激光光束能量的作用下金属吸收剂附近的塑料熔化，所述第一塑件与第二塑件之间的缝隙熔合，从而将第一塑件与第二塑件焊接起来。
本方法采用金属吸收剂代替传统染料作吸收剂，两个塑件之间的焊接面无须涂覆粉末状或液状吸收剂，而放置金属丝、金属膜或金属片代替它即可。采用该方法焊接时，大直径激光光束不需要经过光学透镜严格整形以形成所需的小直径光束，而是直接辐射在金属吸收剂上。金属的光吸收率一般大于塑料的，所以金属的升温速度快于塑料，在金属吸收剂附近的塑料最先熔化、熔合，冷却后形成焊缝，这些焊缝将第一塑件与第二塑件之间的缝隙熔合起来。其它部位的塑料虽受到激光辐射，但因其光吸收率低，大部分激光直接透过塑料，未被吸收转化成热量，所以塑料未熔化不会形成焊缝。
本发明进一步较佳实施例中，所述S100、在第二塑件的待焊接部位上直接放置金属吸收剂，或在第二塑件的待焊接部位上开槽后将金属吸收剂放置于槽内之前还包括：
S400、用酒精去除第一塑件和第二塑件表面的油渍和污物。这样能够有效的避免杂质对焊接质量的影响。
本发明进一步较佳实施例中，所述金属吸收剂为金属丝、金属膜或金属片，所述金属丝宽度为0.2-1.0 mm，厚度为0.1-0.5 mm。
为适应不同形状的塑料焊接件，金属吸收剂除了使用金属丝外，还可以制成片状或薄膜状的形式。如图5和6所示，所述金属膜和金属片上都设置有若干个通孔的多边形。这些金属膜和金属片在有金属的部位激光光束会被吸收，而在没有金属的部位，大部分激光光束直接透过第二塑料。当然所述金属膜和金属片还可以设置成具有若干个通孔的圆形或其他不规则形状。
本发明进一步较佳实施例中，所述金属丝、金属膜和金属片都由导热性良好的铁、铝、铜或其合金制造而成。
本发明进一步较佳实施例中，所述第二塑件为热塑性塑料。所述第一塑件可以为PET，所述第二塑件为PET、PC、PP、PVC、PMMA、PE、POM或PETG。
本发明进一步较佳实施例中，所述激光器为连续近红外半导体激光器，激光波长范围为793-1064 nm，所述连续近红外半导体激光器采用光纤准直器输出，所述连续近红外半导体激光器的最高输出功率为50Ｗ；
本发明进一步较佳实施例中，所述第一塑件和第二塑件被夹持在两块对激光光束高透且耐高温的石英玻璃板之间，并通过两个带可调气压阀的三杆气缸夹紧，该气缸的缸径为25mm。
本发明进一步较佳实施例中，所述激光光束的直径或宽度大于金属吸收剂的宽度。
综上所述，本发明所提供的用于塑件的激光透射焊接方法，包括如下步骤：在第二塑件的待焊接部位上直接放置金属吸收剂，或在第二塑件的待焊接部位上开槽后将金属吸收剂放置于槽内；将第一塑件的待焊接部位压住金属吸收剂后搭接在第二塑件的待焊接部位上，并用夹具将第一塑件、第二塑件夹紧；激光器产生的激光光束对第一塑件的待焊接部位进行一次或多次辐射，所述激光光束穿过第一塑件并对准金属吸收剂，在激光光束能量的作用下金属吸收剂附近的塑料熔化，所述第一塑件与第二塑件之间的缝隙熔合，从而将第一塑件与第二塑件焊接起来，有效地提高了其焊接效率和质量，同时，能够保持美观，焊接成本低，不会烧焦塑料。
显然，以上所描述的实施例仅仅是本申请一部分实施例，而不是全部的实施例，附图中给出了本申请的较佳实施例，但并不限制本申请的专利范围。本申请可以以许多不同的形式来实现，相反地，提供这些实施例的目的是使对本申请的公开内容的理解更加透彻全面。尽管参照前述实施例对本申请进行了详细的说明，对于本领域的技术人员来而言，其依然可以对前述各具体实施方式所记载的技术方案进行修改，或对其中部分技术特征进行等效替换。凡是利用本申请说明书及附图内容所做的等效结构，直接或间接运用在其他相关的技术领域，均同理在本申请专利保护范围之内。
Claims (10)
1.一种用于塑件的激光透射焊接方法，用于第一塑件与第二塑件之间的激光焊接，所述第一塑件为光学透明热塑性塑件，其特征在于，所述用于塑件的激光透射焊接方法包括如下步骤：
在第二塑件的待焊接部位上直接放置金属吸收剂，或在第二塑件的待焊接部位上开槽后将金属吸收剂放置于槽内；
将第一塑件的待焊接部位压住金属吸收剂后搭接在第二塑件的待焊接部位上，并用夹具将第一塑件、第二塑件夹紧；
激光器产生的激光光束对第一塑件的待焊接部位进行一次或多次辐射，所述激光光束穿过第一塑件并对准金属吸收剂，在激光光束能量的作用下金属吸收剂附近的塑料熔化，所述第一塑件与第二塑件之间的缝隙熔合，从而将第一塑件与第二塑件焊接起来。
2.根据权利要求1所述的用于塑件的激光透射焊接方法，其特征在于，所述在第二塑件的待焊接部位上直接放置金属吸收剂，或在第二塑件的待焊接部位上开槽后将金属吸收剂放置于槽内之前还包括：
用酒精去除第一塑件和第二塑件表面的油渍和污物。
3.根据权利要求2所述的用于塑件的激光透射焊接方法，其特征在于，所述金属吸收剂为金属丝、金属膜或金属片。
4.根据权利要求3所述的用于塑件的激光透射焊接方法，其特征在于，所述金属丝的宽度为0.2-1.0 mm，厚度为0.1-0.5 mm。
5.根据权利要求3所述的用于塑件的激光透射焊接方法，其特征在于，所述金属膜和金属片都设置成带有若干个通孔的长方形、圆形或其它不规则形状。
6.根据权利要求5所述的用于塑件的激光透射焊接方法，其特征在于，所述金属膜和金属片都通过激光切割、化学腐蚀、冲床冲压加工制成。
7.根据权利要求1所述的用于塑件的激光透射焊接方法，其特征在于，所述金属吸收剂都由导热性良好的铁、铝、铜或其合金制造而成。
8.根据权利要求1所述的用于塑件的激光透射焊接方法，其特征在于，所述第二塑件为热塑性塑料。
9.根据权利要求1所述的用于塑件的激光透射焊接方法，其特征在于，所述第一塑件和第二塑件被夹持在两块对激光光束高透且耐高温的石英玻璃板之间，并通过两个带可调气压阀的三杆气缸夹紧。
10.根据权利要求1所述的用于塑件的激光透射焊接方法，其特征在于，所述激光器为连续近红外半导体激光器，所述激光光束的直径或宽度大于金属吸收剂的宽度。
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| CN113681909A (zh) * | 2021-08-20 | 2021-11-23 | 深圳技术大学 | 一种激光焊接装置及焊接方法 |
| CN113787255A (zh) * | 2021-09-30 | 2021-12-14 | 苏州大学 | 一种透明塑料薄膜的激光焊接方法 |
| CN114454498A (zh) * | 2021-12-30 | 2022-05-10 | 深圳泰德激光技术股份有限公司 | 一种塑料的激光焊接方法及塑料制品 |
| WO2023231093A1 (zh) * | 2022-05-31 | 2023-12-07 | 苏州大学 | 双波长激光协同实现异种透明塑料连接的方法及装置 |
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| CN113681909A (zh) * | 2021-08-20 | 2021-11-23 | 深圳技术大学 | 一种激光焊接装置及焊接方法 |
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