CN101952108B - 带有u形空隙的超声波焊极 - Google Patents

带有u形空隙的超声波焊极 Download PDF

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CN101952108B
CN101952108B CN200880121261.1A CN200880121261A CN101952108B CN 101952108 B CN101952108 B CN 101952108B CN 200880121261 A CN200880121261 A CN 200880121261A CN 101952108 B CN101952108 B CN 101952108B
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sonotrode
space
gap length
sealing
processed
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CN101952108A (zh
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H·莫格里西
T·凡波勒
U·沃格勒
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Herrmann Ultraschalltechnik GmbH and Co KG
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B29C65/081—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations having a component of vibration not perpendicular to the welding surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
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    • B29C53/48—Bending and joining, e.g. for making hollow articles by bending sheets or strips at right angles to the longitudinal axis of the article being formed and joining the edges for articles of indefinite length, i.e. bending a strip progressively
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract

本发明涉及一种具有用于与所要加工的材料接触的密封表面的超声波焊极(3)。为了提供一种超声波焊极、一种超声波密封设备和一种超声波加工方法，既可避免超声波焊极的复杂且昂贵的定位，又可保证焊缝具有均匀的高质量，建议根据本发明，将密封表面用两部分构造，并且密封表面的两个部分由两个互相面对的密封表面部分形成。

Description

带有U形空隙的超声波焊极
技术领域
本发明涉及超声波焊极。
背景技术
超声波焊极在生产工程中是已知的，例如塑料材料的超声波焊接。
超声波是一种超过可听极限的机械振动。其频率范围从约20kHz开始一直到1GHz。这样的超声波频率往往是从电能通过压电式声换能器(转换器)来产生。借助连接于换能器的超声波焊极，也可能再借助一个振幅变换部分(升幅器)把这种机械振动能量施加于所要所要加工的工件或材料。用于接触所要加工的材料的超声波焊极的表面也被称为焊封表面。
因此，振动结构是由发生器、换能器、选配的升幅器、以及超声波焊极构成。在许多应用场合，换能器和超声波焊极是一体构造的。
在利用超声波加工材料时，一般是把所要加工的材料定位在超声波焊极和一个配对部分或称托背工具(不属于振动结构的组成部分)之间，后者也可称为砧座。然后接触所要加工材料的超声波焊极把超声波能量传递给所要加工的材料，从而进行例如焊接或切割。
在包装领域，通常采用所谓的水平或竖直管状袋子包装机。在这类机器上，片料被从料卷上拉出来，成形为管状，且纵向边缘被密封。然后这样的袋子被充装，进行横向密封，最后切断。所以，横向缝的焊接既生产出被充装了的袋子的头缝也生产出下一个袋子的底缝。水平包装机水平地馈送被包装的物件，所以它们一般仅适用于论件的物品。竖向包装机沿着大致水平的方向馈送物件，因此而适用于松散物料。
纵向的和横向的缝都可以用超声波进行密封。在这种情况中，片料的塑化所需要的热量通过把超声波振动转变成摩擦能量来产生。边界层和分子摩擦意味着热量就此而产生，产生的热量可使塑料材料熔化。在这种情况中，是采用纵向的超声波振动。
在上述管状袋子包装机中，薄膜被卷成围绕着物件的管子形状，使得在沿着输送方向运动的过程中两片薄膜的边缘被弄到一起。重叠的薄膜边缘连续地在超声波焊极和配对部分或称托背工具之间运动，从而它们的纵向的缝被密封。
在这方面，重要的是要使超声波焊极和托背工具(砧座)之间的空隙保持基本上恒定，以确保均匀的焊缝质量。随着振动结构特别是超声波焊极在工作操作过程中逐渐变热，相关的各材料的热膨胀会使所述空隙的尺寸发生变化，以致需要相对于托背工具重新调整超声波焊极的位置。
这种重新调整是非常复杂且昂贵的。此外，这种配置中的超声波焊极和砧座这一对工具占用非常大的空间，特别是还必须布置用于使超声波焊极移动的机构。
发明内容
以所述本领域的状态作为基本的出发点，因此本发明的目的是提供一种超声波焊极、一种超声波密封设备和一种超声波加工方法，其不仅可避免超声波焊极的复杂且昂贵的定位，还可确保焊缝具有均匀的良好质量。
就超声波焊极而言，这一目的是这样来达到的，密封表面是两部分构造，并且密封表面的两个部分由两个互相面对的密封表面部分构成。
换言之，与现有技术的实施例不同，在本发明中，所要加工的材料不再是在超声波焊极的密封表面和托背工具的接触表面之间加工，而是由超声波焊极的密封表面的两个互相面对的密封表面部分来加工。这样就不需要用托背工具了，因此能够免去超声波焊极和托背工具之间的复杂且昂贵的定位操作和间距调整。
因此，可以例如在超声波焊极上设置空隙，其中，两个密封表面部分由该空隙的互相面对的两个壁的各部分形成。因此，材料的加工在空隙内实现。在原理上，空隙可设置在超声波焊极的任何要求的部位。
公认的，各种超声波焊极是本领域现有技术状态中已知的，它具有槽口，但设置槽口仅仅是为了影响超声波焊极的振动特性。而决不是在槽口内加工材料。
在这方面，如果两个密封表面部分是处于大体上互相平行的关系，那将是有利的。
如果空隙基本上在整个表面延伸，那么优点是，可以更容易地使所要加工的片料连续地走过空隙。
如果空隙或空隙宽度向着空隙的底部方向加宽，一方面，这将便于所要加工的材料在空隙里的移动，另一方面，可改善超声波焊极的振动特性。
在一个特别优选的实施例中，该空隙在向着其底部方向有：加工部分，该加工部分具有大致恒定的第一空隙宽度；释放部分，该释放部分具有大致恒定的第二空隙宽度，其中优选的是，第二空隙宽度至少是第一空隙宽度的两倍大，特别优选的是，至少是第一空隙宽度的五倍大。
在一个优选实施例中，加工部分本身沿着空隙的底部方向可包括密封部分和在两侧邻接该密封部分的两个保持部分，空隙在密封部分区域的空隙宽度小于保持部分区域的空隙宽度。应能认识到，保持部分区域的空隙宽度比释放部分区域的空隙宽度小很多。材料的密封或可选的切割仅在密封部分区域进行。保持部分可为材料提供适当的引导。
在一个特别优选的实施例中，加工部分有两个密封部分和布置在两个密封部分之间的保持部分，其中，空隙在密封部分区域的空隙宽度小于保持部分区域的空隙宽度。换言之，在加工部分区域，空隙有两个空隙缩窄处，就是所谓的密封部分。这些焊封部分用于密封缝的生产。所以，如果有一个以上的密封部分，超声波加工可生产出多个平行的密封缝，这对许多应用场合是有利的。
已经发现，也可沿着纵向改变空隙宽度。空隙宽度可有利地沿间隙端部方向变大，这样可以更容易把片料引入空隙。
在一个特别优选的实施例中，空隙沿纵向具有空隙宽度小的中心部分、邻接于该中心部分的相对布置的两端且空隙宽度为中等的两个引导部分、以及两个邻接引导部分的空隙宽度大的两个引入部分。
在原理上，在本发明的实施例中，也不排除通过超声波焊极的温度变化来使空隙宽度变化。也可以形成超声波焊极上的温度梯度，借以改变空隙宽度。
所以，一个优选实施例提供用于调节加工部分的空隙宽度的装置。该装置可以具有例如加热元件以产生超声波焊极内的温度梯度。这样就可通过超声波焊极的局部加热来影响空隙宽度。
替代地，或组合地，超声波焊极可以有多个开口，其中配装有用与超声波焊极的材料膨胀系数不同的材料制成的多个元件。采用膨胀系数不同的两种材料意味着，当超声波焊极的温度升高时，超声波焊极内会产生应力(轻微的)，因而可自动地使与之相关的空隙宽度发生变化，就是说不需要特别主动地采取调节步骤。选择适当的材料和安装位置还可抵消由超声波焊极内产生的温度梯度引起的空隙宽度的变化。
应能认识到，也可提供多个密封表面。这样，例如超声波焊极可以有包括大致互相平行的一排空隙，各所要密封的片料分别被引导通过一排空隙。这样，可用单个超声波焊极同时地加工多个片料。
还可以让密封表面有某种涂层，以降低密封表面和所要加工的材料之间的摩擦系数，进而降低密封表面的磨损。
在一个优选实施例中，换能器布置在超声波焊极的与空隙所在端相反的端面处。这样，通过换能器首先在超声波焊极内产生纵向振动，就是平行于密封表面的振动。但是，由于材料的周期性伸缩，纵向振动总是要引起横向振动。那么把空隙布置成大体上垂直于超声波传播方向，由超声波引起的空隙宽度的变化就受横向振动的影响。试验已经表明，横向振动的振幅取决于槽口的深度。所以在一个优选实施例中，空隙深度与超声波焊极长度之比是在0.02到0.5之间，优选的是在0.03到0.35之间，更优选的是在0.05到0.2之间。
令人惊奇的是，在上述槽口深度下横向振动振幅表现出最大值。槽口深度更大或更小，振幅都将减小。对于35kHz的超声波焊极，最佳横向振动振幅是在4到14μm范围内，较佳的是在8到12μm范围内。
已经发现，密封表面部分是以相位互相相反的关系进行振动，所以在超声波焊极被超声波激励时，槽口的宽度周期性地变化，因而影响材料在空隙内的密封加工。
本发明的超声波焊极设计成完全不需要托背工具。这种超声波焊极本身为一体式，既提供超声波焊极也提供托背工具，在这种情况中，施加振动时，超声波焊极的与所要加工的材料接触的两个表面都起作用，因此不能再区分哪个是振动的超声波焊极哪个是静止的托背工具。
原理上，超声波焊极可以用任何要求的材料生产。钛或例如钢的烧结材料的超声波焊极已经证明是特别适用的。
关于超声波密封设备，用包括换能器和特种超声波焊极的超声波密封设备可达到上述目的，超声波焊极可选地通过变幅器连接到换能器。
在这方面，已经发现，超声波密封设备中的超声波焊极优选的是大致刚性地固定到不是振动结构的构成部分的元件。所以，由换能器、选配的变幅器和超声波焊极构成的振动结构的固定与超声波焊极配合。不属于振动结构的元件这一术语是指在用超声波激励时不起作用因而不产生任何振动的任何元件。应能理解，为了调整的目的，可以移动这个元件。但是这种移动与高速的超声波振动相比是可忽略不计的，所以可以说它是非振动的元件。
总之，让超声波焊极刚性地大致横向对着待形成的密封焊缝比纵向地对着密封焊缝更重要。所以，在一个优选实施例中，把超声波焊极固定于在振动节点处的保持件，这个保持件的设计结构沿超声波焊极的轴线方向，就是在超声波传播方向，是大致刚性的，而沿垂直于超声波焊极轴线的方向，该保持件提供一定的弹性，以使其与来自保持件的超声波振动彻底脱离关系。
本发明还涉及一种用超声波加工材料的方法，其中所要加工的材料与本说明书的开头部分中所述的超声波焊极接触。在这方面，在一个优选实施例中，在加工操作过程中沿纵向将所要加工的材料引导穿过超声波焊极的空隙。在原理上，可对材料进行焊接或切割。
在一个特别优选的实施例中，超声波焊极上的空隙的宽度被选择为小于所要加工的材料的厚度。较佳的是空隙宽度比所要加工的材料厚度小10％到50％之间，更佳的是小20％到40％之间，最佳的的是小约为30％。如果是例如把两片薄膜焊接到一起，所要加工的材料的厚度等于薄膜厚度的两倍。
所以，在用超声波激励超声波焊极同时将所要加工的材料引入空隙。用超声波激励超声波焊极可使空隙宽度内产生周期性的振动而使材料进入空隙。在不用超声波激励的状态，所要加工的材料无法在空隙内移动。只有在用超声波使超声波焊极振动起来之后才能使材料沿着空隙的纵向运动，从而进行超声波加工。
在一个优选实施例中，超声波焊极呈圆的超声波焊极的形式。圆的超声波焊极这一术语是指基本形状为圆形横断面的超声波焊极。一个特别优选的超声波焊极应该是，它在朝向换能器的那一端是圆形超声波焊极的形式，而它的远离换能器的那一端是方块(横断面是长方形的)超声波焊极的形式。
在一个可替代实施例中，把至少一个且优选的是两个密封表面部分布置在连接到超声波焊极的板上。至少一个板可安装有用于设定空隙宽度的调整装置。这个实施例的优点是当焊封表面磨损时，可以只更换一个板或几个板而不必更换整个超声波焊极。
附图说明
本发明的进一步的优点、特点和可能的应用将在下面参照附图进行的某些优选实施例的说明中显现出来，各附图中：
图1示出一台采用本发明的带有超声波焊极的竖向管状袋子包装机；
图2示出图1的放大详图；
图3a-3e示出本发明的超声波焊极的第一实施例的各个视图；
图4a-4e示出本发明的超声波焊极的第二实施例的各个视图；
图5a-5e示出本发明的超声波焊极的第三实施例的各个视图；
图6a-6e示出本发明的超声波焊极的第四实施例；
图7a-7e示出本发明的超声波焊极的第五实施例；
图8a-8e示出本发明的超声波焊极的第六实施例；以及
图9a和9b示出本发明的超声波焊极的第六实施例的两个视图。
具体实施方式
图1示出一台竖向管状袋子包装机。可以看到，所要加工的片料1围绕着管子成形，使得片料的两个边缘被重叠起来。重叠区域以附图标记2标示。互相贴靠的片料边缘被引导通过超声波焊极3上的一个空隙，而超声波焊极3又连接到换能器4和发生器12。发生器12产生高频的电压，由换能器4把高频电压转变成机械振动能量，再由超声波焊极3把机械振动能量传递给片料1。加工连续有效地进行，就是说，片料1沿着箭头的方向连续地运动，从而重叠的片料边缘在图1中超声波焊极3下方焊接到一起。应能理解，也可以进行周期性的运动，其中让片料的行进运动有规律地被中断一例如来施加横向的密封缝。
图2示出图1的放大详图。可以看到，在超声波焊极3的端面4处有空隙5，空隙5在整个端面4上延伸，且片料的边缘的重叠区域2置于空隙5内。尽管换能器4开始时仅向超声波焊极3传递纵向振动，就是说，沿着超声波焊极的纵向轴线方向的振动，但是空隙5允许两端面部分以互相相反的相位关系进行振动，以使槽口宽度由于横向振动而周期性地变化。以这种方式，将重叠的边缘区域焊接到一起而形成纵向的焊缝。
图3a-3e示出本发明的超声波焊极的第一实施例。图3a示出超声波焊极3的端面6的平面图。图3b是剖视图。图中以点划线13表示超声波焊极轴线。超声波焊极3在其远离空隙5的端面6处有固定孔7。固定孔7用于把超声波焊极固定到换能器或可能固定到振幅放大器。可以看出，超声波焊极的尺寸从换能器端朝向空隙端减小。图3c是超声波焊极的侧视图，从该图可清楚地看到端面4上的空隙5。
图3d是图3a的放大详图。可以看到，空隙沿纵向(垂直于超声波焊极轴线)包括空隙宽度小的中心部分8、邻接于中心部分8的相反的两端的空隙宽度中等的两个引导部分8’、以及又邻接于引导部分的空隙宽度大的两个引入部分8”。在这一情况中，中心部分的空隙宽度在整个部分上是大致恒定的，而引导部分的空隙宽度向空隙端部方向扩大。在引入部分8”的区域，空隙宽度突然增大。在加工操作过程中，将所要加工的材料沿着空隙的纵向移动而通过空隙，就是在图3d中从左向右或从右向左移动。因此，材料的移动方向是相对于超声波焊极轴线是横向的。引入部分8”使片料容易引入空隙5。引导部分8’可使所要加工的材料顺畅地抵靠在空隙的表面上，而中心部分8是用于进行片料的加工。在一个优选实施例中，中心部分8那一区域的空隙宽度小于材料厚度，从而只有在超声波焊极被超声波激励时片料才能引入空隙。
图3e是图3c中一部分的放大详图。从该图可看到空隙的深度S。向着空隙5的底部方向，就是在超声波焊极的轴线方向，空隙的宽度也是变化的。沿着空隙的底部方向，空隙包括加工部分9和释放部分10。释放部分内的空隙宽度比加工部分内的空隙宽度大得多。释放部分仅用于使超声波焊极的由空隙5分开的两个端面部分互相分离而产生最佳的横向振动。在空隙的深度S与超声波焊极的长度L之比处在0.05到0.2范围内时，超声波焊极的横向振动为最大。
图4a-4e示出本发明的超声波焊极的第二实施例的各个视图。使用相同的附图标记标示相同的部件。特别是从图4d可以看到，在这一实施例中，中心部分8较短。从图4e可以看到，与图3a-3e表示的实施例相比，加工部分9也明显地缩短了。
图5a-5e示出本发明的超声波焊极的第三实施例。在这一情况中，尽可能地也用相同的附图标记标示相同的部件。从图5c可以看到，狭槽宽度沿横向保持恒定，这不同于前述实施例。
图6a-6e示出本发明的超声波焊极的第四实施例。这一实施例类似于图4a-4e所示的实施例，但这里的空隙深度明显地减小了。
图7a-7e示出本发明的超声波焊极的第五实施例。从图7d可以看到，超声波焊极沿端面4又扩大了，这不同于前述实施例。这种形状有利于优化横向振动的振幅。
图8a和8b概略地示出本发明的超声波焊极的另一实施例。从这里可清楚地看到，超声波焊极3在其端部4的区域引入了两个补偿元件11。这两个补偿元件是用与超声波焊极的材料不同的材料制成的，它们的不同在于具有不同膨胀系数。特别是，图8b的立体图清楚地表示出，由于热量在超声波焊极内产生的温度梯度将对空隙3的加工部分区域的空隙宽度有显著的影响。为了补偿这种的变化，补偿元件11因此适于抵消空隙宽度的变化。
本发明提供一种超声波焊极和一种焊接方法，具体地说，用这种焊极和焊接方法可明显地简化竖向管状袋子包装机。不再需要超声波焊极必须相对于其进行设置可能需要重新调整的专门设置的托背工具。还可使这类密封设备所需要的空间明显减小。
附图标记列表
1片料
2重叠区域
3超声波焊极
4换能器
5空隙
6端面
7固定孔
8中心部分
8’引导部分
8”引入部分
9加工部分
10释放部分
11补偿元件
12发生器
13超声波焊极的轴线

Claims (29)

1.一种超声波焊极，所述超声波焊极具有用于与所要加工的材料接触的密封表面，其特征在于，所述密封表面是两部分构造，并且所述两个密封表面部分是由两个互相面对的密封表面部分形成的，其中，所述超声波焊极的端面有空隙，所述空隙的宽度沿所述空隙的底部方向扩大。
2.如权利要求1所述的超声波焊极，其特征在于，所述两个密封表面部分由两个互相面对的空隙壁的各部分构成。
3.如权利要求1所述的超声波焊极，其特征在于，所述两个密封表面部分是大体上互相平行的构造。
4.如权利要求2或3所述的超声波焊极，其特征在于，所述空隙大致上在整个所述端面延伸。
5.如权利要求1所述的超声波焊极，其特征在于，所述空隙沿所述空隙的底部方向具有第一空隙宽度的加工部分和第二空隙宽度的释放部分，其中，所述第二空隙宽度是所述第一空隙宽度的至少两倍大。
6.如权利要求5所述的超声波焊极，其特征在于，所述第二空隙宽度是所述第一空隙宽度的至少五倍大。
7.如权利要求5所述的超声波焊极，其特征在于，所述加工部分沿所述空隙的底部方向包括密封部分和在两侧邻接所述密封部分的两个保持部分，其中，所述空隙在所述密封部分区域的空隙宽度小于所述保持部分区域的空隙宽度。
8.如权利要求5或7所述的超声波焊极，其特征在于，所述加工部分具有两个密封部分和布置在所述密封部分之间的保持部分，其中，所述空隙在所述密封部分区域的空隙宽度小于所述保持部分区域的空隙宽度。
9.如权利要求2所述的超声波焊极，其特征在于，所述空隙宽度沿着所述空隙端部的方向扩大。
10.如权利要求9所述的超声波焊极，其特征在于，所述空隙沿所述空隙的纵向具有空隙宽度小的中心部分(8)、邻接所述中心部分(8)的相反侧的空隙宽度中等的两个引导部分(8’)、以及邻接所述引导部分的空隙宽度大的两个引入部分(8”)。
11.如权利要求2所述的超声波焊极，其特征在于，所述超声波焊极具有用于调节所述加工部分的所述空隙宽度的装置。
12.如权利要求11所述的超声波焊极，其特征在于，所述调节装置有加热元件，用于产生所述超声波焊极内的温度梯度。
13.如权利要求11或12所述的超声波焊极，其特征在于，所述超声波焊极是用至少两种膨胀系数不同的材料制成的。
14.如权利要求1所述的超声波焊极，其特征在于，设有多个密封表面。
15.如权利要求1所述的超声波焊极，其特征在于，所述各密封表面有涂层。
16.如权利要求1所述的超声波焊极，其特征在于，设有可拆装地固定到所述超声波焊极并承载密封表面部分的至少一个密封元件。
17.如权利要求16所述的超声波焊极，其特征在于，所述至少一个密封元件是可移位的以调整所述两个密封表面部分之间的间距。
18.如权利要求2所述的超声波焊极，其特征在于，所述空隙的深度与所述超声波焊极的长度之比在0.02到0.5的范围内。
19.如权利要求18所述的超声波焊极，其特征在于，所述空隙的深度与所述超声波焊极的长度之比在0.03到0.35的范围内。
20.如权利要求19所述的超声波焊极，其特征在于，所述空隙的深度与所述超声波焊极的长度之比在0.05到0.2的范围内。
21.一种超声波密封设备，包括换能器和如权利要求1至20之一所述的超声波焊极，所述超声波焊极通过变幅器连接到所述换能器。
22.如权利要求21所述的超声波密封设备，其特征在于，所述超声波焊极大致刚性地固定到非振动元件。
23.一种用超声波加工材料的方法，其中，所要加工的材料与两个互相面对的密封表面部分接触，所述密封表面部分沿焊极纵向由空隙的内表面构成，从而在加工操作期间沿纵向将所述材料引导穿过所述空隙。
24.如权利要求23所述的方法，其特征在于，焊接或切割所述材料。
25.如权利要求23所述的方法，其特征在于，所述超声波焊极空隙的宽度小于所要加工的材料的厚度，其中，所述空隙宽度比所述所要加工的材料的所述厚度小10％到50％之间。
26.如权利要求25所述的方法，其特征在于，所述空隙宽度比所述所要加工的材料的所述厚度小20％到40％之间。
27.如权利要求26所述的方法，其特征在于，所述空隙宽度比所述所要加工的材料的所述厚度小30％。
28.如权利要求25至27中任一项所述的方法，其特征在于，在用超声波激励所述超声波焊极的同时将所述所要加工的材料引入所述空隙。
29.如权利要求23所述的方法，其特征在于，所述空隙宽度通过横向振动而变化。
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