塑膠焊接基礎(chǔ)知識(shí)培訓(xùn)一.塑膠焊接方式及應(yīng)用二.焊接結(jié)構(gòu)設(shè)計(jì)三.常用塑膠材料焊接特性1一、方式

1.磨擦式

①超聲波焊接②旋轉(zhuǎn)焊③振動(dòng)磨擦焊常用塑料焊接方式及應(yīng)用2

2.加熱式

3二、應(yīng)用

1.超聲波

①焊接

②鉚焊

4

③.埋植

④.點(diǎn)焊

5

⑤切割\封口

6

2.旋轉(zhuǎn)焊回轉(zhuǎn)體或焊接結(jié)構(gòu)為回轉(zhuǎn)體結(jié)構(gòu)的焊接

7

3.加熱式焊接

①焊接

8

②鉚接9二、常用焊接結(jié)構(gòu)設(shè)計(jì)1.超聲波焊接結(jié)構(gòu)10設(shè)計(jì)要素DesignFactors接口設(shè)計(jì)JointDesign工件設(shè)計(jì)PartDesign11基本的導(dǎo)熔線W4熔接前示意圖W64熔接後示意圖(W=wallthickness)12剪切式熔接ShearJoint熔接前之示意圖熔接深度Interference干涉量

底模最小導(dǎo)入之尺寸0.5mm熔接後之示意圖13剪切式熔接:熔接深度ShearJoint:DepthofWeld推薦值Recommended1.25W最小值Minimum0.5W最大值Maximum1.75W(W=wallthickness)14超音波原理UltrasonicTheory15底模Fixture16換能器振幅ConverterAmplitude40kHz10microns20kHz

20microns15kHz

30microns30kHz15microns17橫向運(yùn)動(dòng)TransverseMotion5”3.5~4”此區(qū)域之振幅為最均勻?yàn)檫吘壣现畽M行運(yùn)動(dòng)之力為工件面上之垂直運(yùn)動(dòng)之力Horn18複合式焊頭(子母焊頭)CompositeHorn19三、常見(jiàn)塑膠焊接特性：1.超聲波焊接20①分析

熱塑性塑料非結(jié)晶性結(jié)（半）結(jié)晶性21比熱溫度結(jié)晶性非結(jié)晶性Amorphous軟化溫度融溶溫度熔化特性22不同塑膠材料間焊接熔融溫度熔融指數(shù)(流率)23常見(jiàn)塑膠焊接性能對(duì)照表材料焊接（近場(chǎng)）焊接（遠(yuǎn)場(chǎng)）鉚合鑲嵌點(diǎn)焊ABSEGEEEABS-聚碳酸酯E-GGGE-GE丙烯酸GG-FFGE丙烯酸共聚物GFGGG242526尼龍GFG-FGF熱塑性聚酯GFFGP高密度聚乙烯F-PPG-FGG聚甲基戊烯-1FF-PG-FGG聚苯硫醚GFPGE聚乙烯FPEGE說(shuō)明：1、E=最佳G=良好F=一般P=較差.

2、焊接面距模面6.4mm以內(nèi)為近場(chǎng)焊接，6.4mm以上為遠(yuǎn)場(chǎng)焊接.

27不同塑膠材料間焊接配比表28基本的需求BasicRequirements最小起始接觸面SmallInitialContact定位對(duì)準(zhǔn)Alignment焊頭的接觸面HornContact29基本概念BasicConcepts

導(dǎo)熔線EnergyDirector剪切Shear30導(dǎo)熔線EnergyDirectorTEMPTIMETEMPTIME31近程Vs遠(yuǎn)程熔接NearField

FirstChoice近程第一選擇FarField

SecondChoice遠(yuǎn)程第二選擇Horn焊頭Horn焊頭32導(dǎo)熔線之優(yōu)點(diǎn)

增加熔接強(qiáng)度IncreaseJointStrength減少溢膠ReducedFlash減少熔接時(shí)間ReducedWeldTime33階梯熔接面StepJoint

BeforeAfter+0.010"to0.025"(0.25to0.64mm)W8W8W3(min.0.023"[0.6mm])SlipFitW4W(min.0.080"[2mm])Note:Radiusallsharpcorners.34咬花面設(shè)計(jì)

EnergyDirectorWithOpposingTexturedSurfacePatentNo.4,618,5160.13～0.29 75μm0.30～0.44 115μm0.45以上 150μmED高度磨面深度35咬花面設(shè)計(jì)

EnergyDirectorwithOpposingTexturedSurface36導(dǎo)熔線之限制對(duì)于（半）結(jié)晶塑料,熔接強(qiáng)度有限，且密封可靠性較差平面度要求較高37剪切式參考設(shè)計(jì)尺寸

零件尺寸

單邊干涉量

最大公差

≤18mm

0.2~0.3mm

+0.025mm

18-35mm

0.3to0.4mm

+0.050mm

≥35mm

0.4to0.5mm

+0.075mm38剪切式熔接之優(yōu)點(diǎn)ShearJointAdvantages創(chuàng)造一個(gè)堅(jiān)固密封保證適用於所有的塑膠材質(zhì)針對(duì)半結(jié)晶性塑膠提早固體化之特性39剪切式之限制ShearJointLimitations緊密公差之要求Requirestighttolerances要求外牆支撐堅(jiān)固良好Requiresrigidside-wallsupport工件尺寸較小Partsizesmall不規(guī)則形狀I(lǐng)rregularshapes40其他設(shè)計(jì)之考慮OtherDesignConsiderations直角/轉(zhuǎn)角SharpCorners孔洞及轉(zhuǎn)折Holes&Bends附屬物Appendages隔膜(薄膜效應(yīng))Diaphragmming焊頭之接觸HornContact41直角/轉(zhuǎn)角SharpCorners

Avoid避免Preferred優(yōu)先選擇42孔洞及轉(zhuǎn)折HolesandBendsSemi-Crystalline

Resins半結(jié)晶塑膠Amorphous

Resins非結(jié)晶塑膠PotentialLackofWeld

inthisArea可能在此區(qū)域無(wú)熔接Void缺口Horn43肢節(jié)潛在性出現(xiàn)斷裂的地方焊頭44焊頭之接觸HornContactCorrect正確CouplingSurface聯(lián)結(jié)接觸面Incorrect不正確TooSmall接觸面太小45焊頭之接觸HornContactFlangeaddedforhorncontactdirectlyoverweldarea針對(duì)焊頭接觸之額外凸緣要垂直地超過(guò)熔接區(qū)域46低型鉚頭LowPro

BeforeAfterD=Studdiameter鉚釘直徑焊頭47咬花成形鉚接KnurledStake

BeforeAfter焊頭48溢膠(平頭)鉚接FlushStake

BeforeAfter焊頭49中空鉚接HollowStake

BeforeAfterD=Studdiameter鉚釘直徑焊頭50埋植Insertion51埋植Insertion52埋植之剖面

CrossSectionOfInsertion53成型Swaging/Forming54成型Swaging/Forming焊頭熔接前示意圖熔接後示意圖55點(diǎn)焊SpotWelding56設(shè)計(jì)考量DesignConsiderations上層材料需比下層材料薄TopSheetThicknessMustBeLessThanBottomSheetThickness材料需平整SheetsShouldBeFlat57點(diǎn)焊之優(yōu)點(diǎn)

AdvantagesofSpotWelding快速之循環(huán)時(shí)間FastCycleTime無(wú)需夾具或溶劑NoExtraFastenersOrAdhesives