SYSTEM AND METHOD FOR WELDING TWO THERMOPLASTIC WORKPIECES

Abstract

A system and method for welding two thermoplastic workpieces. The system has an ultrasonic tool, a support and a cooling unit. The ultrasonic tool is configured to generate mechanical vibrations. The system is configured to clamp together workpieces in the receiving region by the ultrasonic tool and the support if at least one fastening portion of the workpieces opposite one another is arranged in the receiving region. The ultrasonic tool is configured to introduce the mechanical vibrations into the fastening portion of the workpieces to weld the workpieces in a joining zone. The cooling unit is configured to cool, with cooling fluid, at least a part of the fastening portion of the workpieces and/or a cooling portion of the workpieces directly adjacent to the fastening portion.

Claims

1. A system for welding two thermoplastic workpieces, comprising: an ultrasonic tool; a support; and a cooling unit; wherein the ultrasonic tool is configured to generate mechanical vibrations with a frequency of between 20 kHz and 100 kHz, wherein a head of the ultrasonic tool faces the support such that a receiving region for the workpieces is formed between the head of the ultrasonic tool and the support; wherein the system is configured to clamp the workpieces together in the receiving region by the ultrasonic tool and the support when at least one attachment portion of the workpieces has a mutually opposite arrangement in the receiving region; wherein the ultrasonic tool is configured to introduce mechanical vibrations into the attachment portion of the workpieces to weld the workpieces in a joining zone; and wherein the cooling unit is configured to cool at least a part of the attachment portion of the workpieces and/or a cooling portion of the workpieces that directly adjoins the attachment portion using cooling liquid.

2. The system of claim 1, wherein an auxiliary body in the attachment portion between the workpieces when the workpieces are to be clamped together in the receiving region, wherein the two workpieces can be welded by the auxiliary body in the joining zone.

3. The system of claim 1, wherein the cooling liquid is water or at least comprises water.

4. The system of claim 1, wherein the cooling unit has a liquid container, the interior space of which is at least partially filled with cooling liquid, wherein the liquid container is on the support and or a base of the liquid container is at least partially formed by the support, wherein the head of the ultrasonic tool is immersed into the cooling liquid in the interior space of the liquid container such that the receiving space is within the interior space, filled with cooling liquid, of the liquid container.

5. The system of claim 1, wherein the cooling unit is configured to convey the cooling liquid to the attachment portion and/or cooling portion, such that the cooling liquid that has been conveyed flows over the attachment portion and or cooling portion of the workpieces to cool the workpieces.

6. The system of claim 1, wherein the cooling unit has a liquid tank, a pump and a pipeline strand, wherein the cooling unit is configured to convey cooling liquid from the liquid tank through the pipeline strand to a line end of the pipeline strand by the pump, such that the cooling liquid leaving the line end reaches the attachment portion and or cooling portion of the workpieces.

7. The system of claim 1, wherein the system has a first handling unit, to which the ultrasonic tool is attached, wherein the system is configured to control the first handling unit to move the ultrasonic tool along a predetermined movement path relative to the support and or the workpieces.

8. The system of claim 1, wherein the system has a drive which is coupled to the support to move the support along a predetermined drive path, in particular relative to the ultrasonic tool.

9. The system of claim 1, wherein the system has a holding unit, which is configured to hold the workpieces and to arrange the workpieces such that the workpieces are mutually oppositely arranged in the attachment portion and the attachment portion of the workpieces is arranged in the receiving region, wherein the system has a first handling unit, to which the ultrasonic tool is attached, wherein the system is configured to control the first handling unit to move the ultrasonic tool along the workpieces along a predetermined movement path, and wherein the system has a second handling unit, to which the support is attached, wherein the system is configured to control the second handling unit to move the support parallel to the ultrasonic tool.

10. A method for welding two thermoplastic workpieces, wherein the method comprises steps of: a) arranging an attachment portion of the mutually opposite workpieces in a receiving region between a head of an ultrasonic tool and a support, wherein the ultrasonic tool is configured to generate mechanical vibrations with a frequency of between 20 kHz and 100 kHz; b) clamping together the workpieces, which are opposite one another in the attachment portion, by the ultrasonic tool and the support; c) introducing mechanical vibrations into the attachment portion of the workpieces by the ultrasonic tool, such that the workpieces are welded in a joining zone; and d) cooling at least a part of the attachment portion of the workpieces and or a cooling portion of the workpieces that directly adjoins the attachment portion by a cooling unit using a cooling liquid.

11. The method of claim 10, wherein, in step a), a thermoplastic auxiliary plate is arranged in the attachment portion between the workpieces, and wherein, in step c), the two workpieces are welded in the joining zone by the auxiliary plate.

12. The method of claim 10, wherein the cooling liquid is water or at least comprises water.

13. The method of claim 10, wherein steps b), c) and d) are carried out at a same time.

14. The method of claim 1, wherein, in step c), the workpieces are heated in a joining zone to a temperature of at least 150° C., which temperature is at least 20° C. higher than a boiling point of the cooling liquid.

15. The method of claim 10, wherein the cooling unit has a liquid container, an interior space of which is at least partially filled with cooling liquid, wherein the liquid container is on the support and or a base of the liquid container is at least partially formed by the support, wherein, during step c), the head of the ultrasonic tool is immersed into the cooling liquid in the interior space of the liquid container such that the receiving space is within the interior space, filled with cooling liquid, of the liquid container.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Further features, advantages and possible uses of the disclosure herein emerge from the following description of the example embodiments and from the figures. Here, all of the features described and/or illustrated in the figures form the subject matter of the disclosure herein individually and in any desired combination, even independently of the combination of the features in the individual claims or the back-references thereof. Furthermore, in the figures, the same reference signs are used for identical or similar objects.

[0039] FIGS. 1 through 5 each show a schematic illustration of an advantageous embodiment of the system.

[0040] FIG. 6 shows a schematic illustration of a flow diagram of an advantageous embodiment of the method.

DETAILED DESCRIPTION

[0041] FIG. 1 schematically illustrates an advantageous embodiment of the system 2. The system 2 is used to weld two thermoplastic workpieces 4, 6. The system 2 can therefore be used to weld the first workpiece 4 to the second workpiece 6. Each of the two workpieces 4, 6 is a thermoplastic workpiece. In this respect, each of the two workpieces 4, 6 may consist of thermoplastic material or at least comprise thermoplastic material. Each of the two workpieces 4, 6 may comprise reinforcing fibers, which are embedded in thermoplastic material of the respective workpiece 4, 6. When reference is made below to welding of the two workpieces 4, 6, this can be understood to mean direct welding of thermoplastic material of the first workpiece 4 to thermoplastic material of the second workpiece 6. The welding of the two workpieces 4, 6 may, however, also be understood to mean that the two workpieces 4, 6 are welded by way of further thermoplastic material, which is arranged between the two workpieces 4, 6 before the welding operation. Thus, for example, a thermoplastic auxiliary plate 26 may be arranged between the first workpiece 4 and the second workpiece 6 before the two workpieces 4, 6 are actually welded by way of thermoplastic material of the auxiliary plate 26. The auxiliary thermoplastic material arranged between the two workpieces 4, 6 may also be understood to mean what is known as an energy directing element or what is known as an “energy director”. The two workpieces 4, 6 are welded by ultrasonic welding. The welding may thus also be understood to mean ultrasonic welding. The welding is achieved by virtue of mechanical vibrations with a frequency of between 20 kHz and 100 kHz, which results in heating of thermoplastic material between the workpieces 4, 6 or between the auxiliary plate 26 and the workpieces 4, 6 on account of molecular and/or interface friction, which heating reaches a temperature at which thermoplastic material softens and/or melts. However, it is preferably provided that the heating is restricted to a temperature at which thermoplastic material, the two workpieces 4, 6 and preferably also thermoplastic material of the auxiliary plate 26 transitions into a plastic flow, but without thermoplastic material melting down. The flow is sufficient to create a material bond between thermoplastic material of the auxiliary plate 26 and thermoplastic material of each of the two workpieces 4, 6. Should the welding take place directly between the two workpieces 4, 6, the plastic flow of thermoplastic material of the two workpieces 4, 6 results in a material bond between the two workpieces 4, 6.

[0042] In order to generate the mechanical vibrations for welding the two thermoplastic workpieces 4, 6, the system 2 comprises an ultrasonic tool 8. A head of the ultrasonic tool 8 presses directly on one of the two workpieces 4, 6 in order to transmit the mechanical vibrations and to generate the clamping force. The ultrasonic tool 8 may have what is known as a converter 48, a booster 50 and a sonotrode 52. The converter 48, the booster 50 and the sonotrode 52 are preferably arranged one behind the other and mechanically coupled to one another in a mechanical series circuit. The converter 48 may be designed to convert an electrical signal into mechanical vibrations. Mechanical vibrations can therefore be generated by the converter 48. For this purpose, the converter 48 may have piezo elements, for example, which can be actuated by an electrical signal, this resulting in mechanical vibrations insofar as the electrical signal is an alternating signal. The booster 50 is preferably designed to change the amplitude of the mechanical vibrations generated by the converter 48 in terms of the amplitude level and/or frequency. The booster 50 can thus be designed in such a way, for example, that the booster 50 can be made to mechanically vibrate only in the frequency range of between 20 kHz and 100 kHz. The sonotrode 52 is mechanically coupled to the booster 50. The sonotrode 52 has a head 14, which is designed to be brought in direct contact with one of the two workpieces 4, 6 in order to accomplish the welding. The head 14 of the sonotrode 52 may also form the head 14 of the ultrasonic tool 8. In order to set the ultrasonic tool 8 in mechanical vibration, the ultrasonic tool 8 may be coupled via an electrical connecting line to a control unit 46, which is designed to generate and transmit an electrical signal to the ultrasonic tool 8 via the connecting line, such that the ultrasonic tool 8 is set in mechanical vibration by virtue of the electrical signal. The control unit 46 does not form part of the system 2. The ultrasonic tool 8 is designed to generate mechanical vibrations with a frequency of between 20 kHz and 100 kHz, preferably of between 20 kHz and 40 kHz.

[0043] The system 2 furthermore has a support 10. The support 10 is illustrated schematically and by way of example in FIG. 1. The support 10 may be designed in the manner of an anvil or as a table. The support 10 may, however, also be formed by a frame or another solid body. The support 10 is often significantly larger than the sonotrode 52. This is because the support 10 may also be designed to hold and/or attach the workpieces 4, 6 in a supporting manner. In particular, the support 10 may be designed to detachably hold the workpieces 4, 6, although this is not illustrated schematically in FIG. 1.

[0044] The head 14 of the ultrasonic tool 8 is arranged facing the support 10 in such a way that a receiving region 16 for the workpieces 4, 6 is formed between the head 14 of the ultrasonic tool 8 and the support 10. The workpieces 4, 6 may thus be arranged between the head 14 of the ultrasonic tool 8 and the support 10, with the result that an attachment portion 18 of the two workpieces 4, 6 is arranged between the head 14 of the ultrasonic tool 8 and the support 10. In this case, at least a part of the attachment portion 18 of the two workpieces 4, 6 is arranged in the receiving region 16 between the head 14 of the ultrasonic tool 8 and the support 10. The system 2 is furthermore designed to clamp the workpieces 4, 6 together in the receiving region 16 by the ultrasonic tool 8 and the support 10. For this purpose, the ultrasonic tool 8 can be attached to a handling unit 42, as can be seen schematically in FIG. 4. The head 14 of the ultrasonic tool 8 can press on one of the two workpieces 4, 6 by the handling unit 42, with the result that the two workpieces 4, 6 are clamped in between the head 14 of the ultrasonic tool 8 and the support 10. The receiving region 16 is preferably determined by the contact surface area between the head 14 of the ultrasonic tool 8 and the longitudinal axial direction of the ultrasonic tool 8. This is because the ultrasonic tool 8 is preferably designed to introduce the mechanical vibrations into the clamped-together workpieces 4, 6 in the longitudinal axial direction of the ultrasonic tool 8. This is preferably performed over the entire contact surface area between the head 14 and the one of the two workpieces 4, 6. Outside the receiving region 16, the mechanical vibrations will only occur to a lesser degree, and therefore the workpieces 4, 6 can be welded in a targeted manner in the receiving region 16. The ultrasonic tool 8 is therefore designed to introduce the mechanical vibrations into that part of the attachment portion 18 of the workpieces 4, 6 that overlaps with the receiving region 16, in order to weld the workpieces 4, 6 in a joining zone 20. The joining zone 20 is preferably within the receiving region 16. If the two workpieces 4, 6 are welded by way of the auxiliary plate 26 arranged between the two workpieces 4, 6, the respective joining zone 20 will be on the boundary layers between the auxiliary plate 26 and the workpieces 4, 6 within the receiving region 16. This is because the molecular and interface friction on account of the mechanical vibrations occurs precisely at the transition regions from the auxiliary plate 26 to the respective workpiece 4, 6, this resulting in the desired heating of thermoplastic material of the auxiliary plate 26 or of the respective workpiece 4, 6. The ultrasonic welding therefore takes place in the joining zone 20.

[0045] The ultrasonic tool may be moved along a predetermined movement path relative to the support 10 and/or the workpiece 4, 6. The receiving region 16 and the joining zone 20 are displaced synchronously with the movement of the ultrasonic tool 8. That part of the welded workpieces 4, 6 that has been pushed out of the receiving region 16 may, however, still be very warm at the weld seam. In order to prevent this weld seam, which is still very warm, from being destroyed and/or mechanically adversely affected because of the outwardly conveyed mechanical vibrations, the system 2 has a cooling unit 12. The cooling unit 12 is designed to cool at least a part of the attachment portion 18 of the workpieces 4, 6 and/or a cooling portion 24 of the workpieces 4, 6 that directly adjoins the attachment portion 18 using cooling liquid 22. That part of the attachment portion 18 that can be cooled using cooling liquid 22 is preferably arranged on the outside around the receiving region 16, in particular annularly. The cooling portion 24 may in turn be arranged on the outside of the attachment portion 18, specifically preferably also annularly.

[0046] FIG. 1 illustrates an advantageous embodiment of the cooling unit 12. In this respect, the cooling unit 12 may have, for example, a liquid tank 28, a pump 30 and a pipeline strand 32. The pipeline strand 32 preferably extends from the liquid tank 28 to a line end 34, the pump 30 being integrated in the pipeline strand 32. Cooling liquid 22 can thus be conveyed from the liquid container 36 to the line end 34 by the pump 30. The line end 34 is preferably arranged in such a way that the cooling liquid 22 leaving the line end 34 reaches the attachment portion 18 and/or cooling portion 24 of the workpieces 4, 6. The system 2 may also have a plurality of cooling units 12. This is illustrated by way of example in FIG. 1. That part of the attachment portion 18 which is on the outside of the receiving region 16 is cooled down particularly quickly and efficiently by the cooling liquid 22. In addition, the cooling portion 24 of the workpieces 4, 6 is also efficiently cooled down by the cooling liquid 22.

[0047] If the sonotrode 52 is used to produce a weld seam, such that the sonotrode 52 is moved along the predetermined movement path relative to the support 10 and/or the workpieces 4, 6, the weld seam that is continuously pushed out of the joining zone 20 in the process is quickly and efficiently cooled down by virtue of the cooling using the cooling liquid 22. Mechanical vibrations which are transmitted from the receiving region 16 outward into the aforementioned part of the attachment portion 18 or even into the cooling portion 24 therefore cannot result in destruction of the aforementioned weld seam. This is because the weld seam solidifies and thus increases in strength as a result of being cooled down. This higher strength prevents the aforementioned mechanical vibrations from causing destruction of and/or having an adverse mechanical effect on the weld seam.

[0048] FIG. 3 schematically illustrates a further advantageous embodiment of the system 2. Except for the support 10, the system 2 corresponds to the system 2 explained above in conjunction with FIG. 1. Similar reference is therefore made to the corresponding explanations.

[0049] The support 10 for the system 2 illustrated in FIG. 2 has a smaller configuration than the support 10 as was used before. In particular, the support 10 may have a base area by way of which the support 10 presses against the second workpiece 6. The sonotrode 52 may press against the first workpiece 4 with the same base area. The support 10 and the sonotrode 52 may be arranged opposite one another, with the result that the portion that is in line between the base areas determines the receiving region 16.

[0050] FIG. 3 schematically illustrates a further advantageous embodiment of the system 2. Except for the cooling unit 12, the system 2 corresponds to the system 2 explained above in conjunction with FIG. 1. Similar reference is therefore made to the corresponding explanations.

[0051] The cooling unit 12 of the system 2, as is illustrated schematically in FIG. 3, comprises a liquid container 36, the interior space 38 of which is at least partially filled with the cooling liquid 22. The liquid container 36 is arranged on the support 10. In addition, the head 14 of the ultrasonic tool 8 is immersed in the cooling liquid 22 in the interior space 38 of the liquid container 36 with the result that the receiving region 16 is within the interior space 38, filled with cooling liquid 22, of the liquid container 36. The workpieces 4, 6 and the auxiliary plate 26, which is preferably arranged in between, are likewise immersed in the cooling liquid 22, such that the attachment portion 18 and the cooling portions 24 are within the interior space 38, filled with cooling liquid 22, of the liquid container 36. In other words, it is preferably provided that the receiving region 16 and also the attachment portion 18 and the cooling portion 24 are below the surface of the cooling liquid 22. The base 40 of the liquid container 36 is arranged between the support 10 and the workpieces 4, 6. However, this is not disadvantageous because the workpieces 4, 6 and preferably also thermoplastic auxiliary plate 26 arranged in between may be clamped in between the ultrasonic tool 8 and the support 10 in the receiving region 16. In an embodiment variant not illustrated in FIG. 3, the base 40 of the liquid container 36 may be formed by the support 10.

[0052] If mechanical vibrations are introduced into the receiving region 16 by the ultrasonic tool 8, the joining zone 20 is created between the clamped-in workpieces 4, 6. The cooling liquid 22 evaporates because of the strong heating in the joining zone 20 or evaporates before it reaches the joining zone 20, with the result that the welding in the joining zone 20 is not adversely affected by the cooling liquid 22. The cooling liquid 22 is preferably water or at least comprises water. The cooling liquid 22 may be formed on the basis of water with additional substances, for example. In the joining zone 20, a temperature that is often greater than 150° C. is produced on account of the heating. This causes the cooling liquid 22 to evaporate, in particular if the cooling liquid 22 is water or is based on water.

[0053] As that part of the attachment portion 18 that is arranged around the joining zone 20, and the cooling portion 24, are arranged in the cooling liquid 22, particularly rapid and efficient cooling-down will also take place here. This in turn results in a weld seam that has been pushed out of the joining zone 20 cooling down particularly efficiently and quickly, and therefore the weld seam is protected against mechanical effects or mechanical destruction caused by mechanical vibrations.

[0054] FIG. 4 illustrates a further advantageous embodiment of the system 2. The system 2 corresponds at least substantially to the system 2 explained in conjunction with FIG. 3. However, the system 2 from FIG. 4 comprises a first handling unit 42, to which the ultrasonic tool 8 is attached. The first handling unit 42 may be in the form of a robot with a robot arm 54. The ultrasonic tool 8 is attached to an arm end 56 of the robot arm 54. The first handling unit 42 is designed to spatially move the ultrasonic tool 8. Furthermore, the ultrasonic tool 8 can press on the workpieces 4, 6 by the first handling unit 42 in such a way that the workpieces 4, 6, and in particular also the auxiliary plate 26 arranged in between, are clamped in between the head 14 of the ultrasonic tool 8 and the support 10. In addition, the system 2 is designed to control the first handling unit 42 in such a way as to move the ultrasonic tool 8 along a predetermined movement path relative to the support 10 and the workpieces 4, 6. For this purpose, the first handling unit 42 may be coupled to the control unit 46 via a control line. Consequently, the system 2 can control the first handling unit 42 by the control unit 46 in such a way as to move the ultrasonic tool 8 along the predetermined movement path. In the process, contact between the head 14 and the workpieces 4, 6 is maintained. During the movement of the ultrasonic tool 8, the workpieces 4, 6 thus continue to be pressed together. The movement of the ultrasonic tool 8 creates a weld seam for joining the workpieces 4, 6, in particular using the auxiliary plate 26. In this case, the workpieces 4, 6 can be detachably held directly or indirectly on the support 10 in order to prevent the workpieces 4, 6 from slipping when the ultrasonic tool 8 is moving.

[0055] FIG. 5 illustrates a further advantageous embodiment of the system 2. The system 2 illustrated in FIG. 5 substantially corresponds to the system 2, as has been explained in conjunction with FIG. 3. Similar reference is made to the corresponding explanations. The system 2 illustrated in FIG. 5, however, has a drive 44 which is coupled to the support 10 in such a way as to move the support 10 along a predetermined drive path, preferably relative to the ultrasonic tool 8. The drive 44 is preferably in the form of a linear drive 44. The support 10 can thus be moved for example in a plane by the linear drive 44. The drive 44 may be controlled by the control unit 46. For this purpose, the control unit 46 may be coupled to the drive 44 via a signal control line (not illustrated). While the support 10 is moved by the drive 44, the ultrasonic tool 8 may be arranged in a stationary manner and/or held stationary. For this purpose, a holding device (not illustrated) may be provided, which holds the ultrasonic tool 8 stationary. In addition, it may be provided that the workpieces 4, 6 are held directly or indirectly by the support 10 and/or in the liquid container 36 in order to prevent the workpieces 4, 6 from slipping during the movement of the support 10 by the drive 44. The movement of the support 10 by the drive 44 therefore also results in an analogous movement of the workpieces 4, 6, specifically preferably relative to the ultrasonic tool 8. This makes it possible to obtain a weld seam between the workpieces 4, 6, in particular by way of the auxiliary plate 26.

[0056] FIG. 6 schematically illustrates a flow diagram of an advantageous embodiment of the method. The method is used to weld thermoplastic workpieces 4, 6. In this respect, the method comprises the following steps a) to d): [0057] a) arranging an attachment portion 18 of the mutually opposite workpieces 4, 6 and a receiving region 16 between a head 14 of an ultrasonic tool 8 and a support 10, wherein the ultrasonic tool 8 is designed to generate mechanical vibrations with a frequency of between 20 kHz and 100 kHz; [0058] b) clamping together the workpieces 4, 6, which are opposite one another in the attachment portion 18, by the ultrasonic tool 8 and the support 10; [0059] c) introducing mechanical vibrations into the attachment portion 18 of the workpieces 4, 6 by the ultrasonic tool 8, with the result that the workpieces 4, 6 are welded in a joining zone 20; [0060] d) cooling at least a part of the attachment portion 18 of the workpieces 4, 6 and/or a cooling portion 24 of the workpieces 4, 6 that directly adjoins the attachment portion 18 by a cooling unit 12 using a cooling liquid 22.

[0061] The method discussed achieves similar advantages and/or effects to those that have already been explained in conjunction with the system 2. For the method, similar reference is also made to the advantageous explanations, preferred features, effects and/or advantages as have been explained in conjunction with the system 2.

[0062] Steps b), c) and d) are preferably carried out at the same time. As a result, the workpieces 4, 6 are welded in the joining zone 20, while the workpieces 4, 6 are clamped together in the attachment portion 18 by the ultrasonic tool 8 and the support 10. Furthermore, the cooling down by the cooling liquid 22 is performed at the same time.

[0063] While at least one example embodiment of the invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the example embodiment(s). In addition, in this disclosure, the terms “having”, “comprise” or “comprising” do not exclude other elements or steps, the terms “a”, “an” or “one” do not exclude a plural number, and the term “or” means either or both. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. This disclosure hereby incorporates by reference the complete disclosure of any patent or application from which it claims benefit or priority.