塑料焊接培訓(xùn)

塑膠焊接基礎(chǔ)知識培訓(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.加熱式

二、應(yīng)用

1.超聲波

①焊接

②鉚焊

③.埋植

④.點(diǎn)焊

⑤切割\封口

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

3.加熱式焊接

①焊接

②鉚接二、常用焊接結(jié)構(gòu)設(shè)計(jì)1.超聲波焊接結(jié)構(gòu)設(shè)計(jì)要素DesignFactors接口設(shè)計(jì)JointDesign工件設(shè)計(jì)PartDesign基本的導(dǎo)熔線線W4熔接前示意圖W64熔接後示意圖(W=wallthickness)剪切式熔接ShearJoint熔接前之示意意圖熔接深度Interference干涉量

底模最小導(dǎo)入之尺寸0.5mm熔接後之示意意圖剪切式熔接:熔接深度ShearJoint:DepthofWeld推薦值Recommended1.25W最小值Minimum0.5W最大值Maximum1.75W(W=wallthickness)超音波原理UltrasonicTheory底模Fixture換能器振幅ConverterAmplitude40kHz10microns20kHz20microns15kHz30microns30kHz15microns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Horn複合式焊頭(子母焊頭)CompositeHorn三、常見塑膠膠焊接特性：：1.超聲波焊接①分析熱塑性塑料非結(jié)晶性結(jié)（半）結(jié)晶性比熱溫度結(jié)晶性非結(jié)晶性Amorphous軟化溫度融溶溫度熔化特性不同塑膠材料間焊焊接熔融溫度熔融指數(shù)(流流率)常見塑膠焊接接性能對照表表材料焊接（近場）焊接（遠(yuǎn)場）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GFGGG丁二烯一苯乙烯共聚物GFGGGCACABCAPF-PPGGF-P聚酰胺酰亞胺GF

聚碳酸酯GGG-FGG聚苯乙烯EEFG-EE改性橡膠GG-FEEE聚砜GFG-FGFPVCF-PPGEG-F苯乙烯－丙烯腈共聚物EEFGG-F聚甲醛GFG-FGF含氟聚合物P

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說明：1、E=最佳G=良好F=一般P=較差.2、焊接面距模模面6.4mm以內(nèi)為近場焊焊接，6.4mm以上為遠(yuǎn)場焊焊接.不同塑膠材料料間焊接配比比表基本的需求BasicRequirements最小起始接觸觸面SmallInitialContact定位對準(zhǔn)Alignment焊頭的接觸面面HornContact基本概念BasicConcepts導(dǎo)熔線EnergyDirector剪切Shear導(dǎo)熔線EnergyDirectorTEMPTIMETEMPTIME近程Vs遠(yuǎn)程熔接NearFieldFirstChoice近程第一選擇擇FarFieldSecondChoice遠(yuǎn)程第二選擇擇Horn焊頭Horn焊頭導(dǎo)熔線之優(yōu)點(diǎn)點(diǎn)增加熔接強(qiáng)度度IncreaseJointStrength減少溢膠ReducedFlash減少熔接時(shí)間間ReducedWeldTime階梯熔接面StepJointBeforeAfter+0.010"to0.025"(0.25to0.64mm)W8W8W3(min.0.023"[0.6mm])SlipFitW4W(min.0.080"[2mm])Note:Radiusallsharpcorners.咬花面設(shè)計(jì)EnergyDirectorWithOpposingTexturedSurfacePatentNo.4,618,5160.13～0.2975μμm0.30～0.44115μm0.45以上150μmED高度磨面深度咬花面設(shè)計(jì)EnergyDirectorwithOpposingTexturedSurface導(dǎo)熔線之限制制對于（半）結(jié)晶塑料,熔接強(qiáng)度度有限，且密封可靠性性較差平面度要求較較高剪切式參考設(shè)計(jì)尺寸寸零件尺寸單邊干涉量最大公差≤18mm0.2~0.3mm+0.025mm18-35mm0.3to0.4mm+0.050mm≥35mm0.4to0.5mm+0.075mm剪切式熔接之之優(yōu)點(diǎn)ShearJointAdvantages創(chuàng)造一個(gè)堅(jiān)固固密封保證適用於所有的的塑膠材質(zhì)針對半結(jié)晶性性塑膠提早固固體化之特性性剪切式之限制制ShearJointLimitations緊密公差之要要求Requirestighttolerances要求外牆支撐撐堅(jiān)固良好Requiresrigidside-wallsupport工件尺寸較小小Partsizesmall不規(guī)則形狀I(lǐng)rregularshapes其他設(shè)計(jì)之考考慮OtherDesignConsiderations直角/轉(zhuǎn)轉(zhuǎn)角SharpCorners孔洞及轉(zhuǎn)折Holes&Bends附屬物Appendages隔膜(薄膜膜效應(yīng))Diaphragmming焊頭之接觸HornContact直角/轉(zhuǎn)轉(zhuǎn)角SharpCornersAvoid避免Preferred優(yōu)先選擇孔洞及轉(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)域無熔接Void缺口Horn肢節(jié)潛在性出現(xiàn)斷裂裂的地方焊頭焊頭之接觸HornContactCorrect正確CouplingSurface聯(lián)結(jié)接觸面Incorrect不正確TooSmall接觸面太小焊頭之接觸HornContactFlangeaddedforhorncontactdirectlyoverweldarea針對焊頭接觸觸之額外凸緣緣要垂直地超超過熔接區(qū)域域低型鉚頭LowProfileStakeBeforeAfterD=Studdiameter鉚釘直徑焊頭咬花成形鉚接接KnurledStakeBeforeAfter焊頭溢膠(平頭)鉚接FlushStakeBeforeAfter焊頭中空鉚接HollowStakeBeforeAfterD=Studdiameter鉚釘直徑焊頭頭埋植植Insertion埋植植Insertion埋植植之之剖剖面面CrossSectionOfInsertion成型型Swaging/Forming成型型Swaging/Forming焊頭熔接接前前示示意意圖圖熔接接後後示示意意圖圖點(diǎn)焊焊SpotWelding設(shè)計(jì)計(jì)考考量量DesignConsiderations上層層材材料料需需比比下下層層材材料料薄薄TopSheetThicknessMustBeLessThanBottomSheetThickness材料料需需平平整整SheetsShouldBeFlat點(diǎn)焊焊之之優(yōu)優(yōu)點(diǎn)點(diǎn)AdvantagesofSpotWelding快速速之之循循環(huán)環(huán)時(shí)時(shí)間間FastCycleTime無需需夾夾具具或或溶溶劑劑NoExtraFastenersOrAdhesivesNeeded無需需特特殊殊治治具具(一一般般而而言言)NoSpecialFixturingRequired(Generally)無需需接接口口設(shè)設(shè)計(jì)計(jì)MoldedJointDesignUnnecessary可以以手手焊焊