CN1041391C - 一种将可热活化的聚合物组合物施加到基材上的方法、装置以及所制得的制品 - Google Patents

一种将可热活化的聚合物组合物施加到基材上的方法、装置以及所制得的制品 Download PDF

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CN1041391C
CN1041391C CN94191052A CN94191052A CN1041391C CN 1041391 C CN1041391 C CN 1041391C CN 94191052 A CN94191052 A CN 94191052A CN 94191052 A CN94191052 A CN 94191052A CN 1041391 C CN1041391 C CN 1041391C
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克雷格·A·内夫
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Abstract

将如热熔粘合剂这样的可挤出材料施用至基材上，同时通过激光束进行辐照。激光的能量被粘合剂和基材吸收，从而使粘合剂渗入织物。当施用于两基片之间的缝隙上时，可挤出材料产生了非常牢固的粘合。当其中之一的基材是多孔材料时，可挤出材料将透过该多孔材料，与下面的层接触，从而形成粘合。可挤出材料是通过喷嘴施用的，而激光束与可挤出材料的流径同轴地被导引通过该喷嘴。同轴布置有利于在复杂型式时喷嘴和激光束的移动，并能保证同时施用可挤出材料和激光束。

Description

一种将可热活化的聚合物组合物施加到基材上的方法、装置以及所制得的制品
本发明涉及在基材上施用加热组合物领域。在优选的实施方案中，本发明涉及利用可挤出的介质如热熔粘合剂将片材粘结在一起的技术。
已知有各种加热活化的组合物。例如，一种常用的组合物是热熔粘合剂，首先将它加热成液体或其它可流动状态，然后施用于要固定在一起的两个制品上。随着冷却，该组合物变得坚固，并提供将两个制品固定在一定的粘合性能。使用热熔粘合剂将两个合成材料的片材固定在一起已在本人早些时候的美国专利US4,861,401中得到描述。
根据这份早些时候的专利，该粘合剂组合物也是通过激光束进行辐照的；在粘合剂沉积在要被固定在一起的片材上之后，所述的激光束照射到粘合线上。辐照有助于在粘合剂和材料之间获得良好的粘合。
在表面硬化材料施用于金属基材上之前，将其进行辐照被披露在US4,644,127(LaRocca)中。
预处理要被粘合的表面(见US4,931,125，Volkmann等人)和使用激光加热并粘合热塑性片材(见US4,069,080，Os-borne；US4,636,609，Nakamata；和US4,029,535，Cannon)也是已知的。
现有技术存在着若干个缺点。例如，US4,861,404所告知的技术使激光能不能在粘合剂沉积之前帮助其熔化；除直线外不能调节粘合型式；在施加粘合剂和通过激光的随后的加热之间使得粘合剂有可能冷却。尽管LaRocca的专利披露了对要被施加至表面上的金属组合物的激光熔化，但是在组合物和激光束之间只能有最小程度的接触，因此，不便于下面复杂的型式。
本发明的目的之一是提供一种将可热化的聚合物组合物施用于基材上的方法，该方法包括将所述的组合物以液态供至将所述组合物分散在所述基材上的流径中，并同时用能束辐照在所述流径中的所述组合物，其中所述的能束被定形成与所述流径相同的形状，并直接导入所说流径中的所述组合物中，从而将所述能束的能量传递至所述的组合物上，并且在所述组合物施用至基材上之后将能量传递到该基材上，以加热该基材。
本发明的另一目的是提供一种将可热活化的聚合物组合物施用于基材上的装置，该装置包括形成流径的设备，该设备用来接收液态的所述组合物并用来沿所述的流径将所述的组合物导引至所述的基材上；以及另一设备，该设备用来将能束定形成与所述流径相同的形状，并将所述能束直接导入所述流径内的所述组合物中并导引至所述基材上，以辐照在所述流径中的所述的组合物，从而将所述能束的能量传递至所述的组合物上，并在所述组合物施用于所述基材上之后用所述能束辐照所述的基材。
本发明的再一目的是提供由将可热活化的聚合物组合物施用于基材上的方法所制得的产品。
根据本发明，在组合物施用于基材上之前，通过将其通过把组合物的流径和电磁能束的光径相结合的喷嘴而加热该组合物。在优选的实施方案中，该组合物是热熔粘合剂，能束是由钇铝石榴石激光得到的。
通过横切流径延伸的通道，该喷嘴的流径装有液体粘合剂。该流径可以是圆柱形的，但优选是圆锥形的，以提供用于粘合剂的窄小的排出口。流径排出口的另一端由允许激光束进入流径的光学窗口组成。将该光学窗口和流径进行定向，以致使激光束和流径共轴。该光学窗口可以是平面的，但优选具有弯曲的表面，以提供光能，从而使激光束能以与喷嘴的圆锥角相同的角度进行聚集。这种布局能最大程度的将能量送至粘合剂上，防止喷嘴侧壁和激光束之间的相互作用，而且能同时加热基材和粘合剂。
喷嘴的排出口可以是圆形的或伸长的。如果使用伸长排出口的话，光学窗是圆柱形的，以便激光束的形式与排出口的形状相匹配。例如，对于在较宽的表面区域上沉积可挤出的材料而言，应使用伸长排出口，该喷嘴将沿横截伸长开口方向的方向在该表面上移动。
因为能束和粘合剂是重合的，所以它们能容易地相对于基材移动。在优选的实施方案中，基材连接至由数字式线性电机驱动的并由计算机控制的X-Y工作台上。
选择流径的物理尺寸(例如其长度和横截面)，以提供激光和粘合剂间希望的相互作用以及基材上所希望的粘合剂珠粒的尺寸。粘合剂和激光之间的相互作用还通过粘合剂的吸收特性和激光的光谱来确定。而且，当设计喷嘴时要考虑这个因素。申请人发现，当粘合剂为尼龙，能束由150W的钇铝石榴石激光器产生时，提供流径的长度为0.5英寸、直径为0.09英寸的喷嘴能提供出良好的结果。
喷嘴可以安装在支架上，使之能拆卸并能用另一不同尺寸的喷嘴替代，使得有可能对不同厚度和种类的材料来调节喷嘴。
优选只在其供至用来输入到喷嘴的之前加热粘合剂，从而以可流动态装入之。这省去了需要向粘合剂中添加化学品，这些化学品通常被要求用来防止由于加热的粘合剂和空气之间的相互作用而造成的降能，因此，本发明提供了更纯的粘合剂。
要被固定在一起的片材可以是相互邻接的，在这种场合，粘合剂放置在接触线上。然而，如果一层(或多层)片材是多孔的话，可以将粘合剂放置在其它片材的顶上，使粘合剂穿过该片材而达到下面的片材上。
图1是本发明的流程图，示出了在目的基材上同时施加电磁能束和可挤出材料。
图2是本发明优选实施方案的横截面图。
图3是图示说明了根据本发明用可挤出材料粘合两个片材。
图4图示说明了根据本发明用可挤出材料进行粘合的另一实施方案。
图5图示说明了根据本发明用可挤出材料进行粘合的又一实施方案。
图6图示说明了根据本发明用可挤出材料通过多孔目的材料进行粘合。
图1是图示说明本发明原理的流程图。可挤出材料1施加至目的基材2接触部位的表面上，电磁能束3射到该基材的辐照部位上。辐照点5十分接近接触点4，因此，可挤出材料被能束加热，而保持液体或半液体状。如果将可挤出材料暴露至环境条件搁置一段时间的话，随着溶剂的损失或冷却，通常将丧失这种液体或半液体状态。如果辐照点和材料的接触点分离至这样的程度，以致使可挤出材料过快地丧失其液体或半液体状态，那么将阻止该可挤出材料最大程度地渗入目的材料中。优选该材料的接触点和辐照点重合。
图2是本发明优选实施方案的纵截面图。如该图所示，材料接触点与照点在施加点6处重合。因此，可挤出材料过快地冷却和改变其状态的可能性被减至最小程度。储存器7含有可挤出材料1，例如热熔粘合剂，储存器的大小和性能随可挤出材料的性质而变化。如果可挤出材料是热塑性的，那么该储存器将装有熔融该材料的加热器。如果可挤出材料是有很大蒸汽压的溶剂基化学体系或化学品，那么该储存器将是密闭的，以防止可挤出材料从储存器中逸出。如果可挤出材料是水或空气固化的胶液，那么储存器将是密闭的，以防止对可挤出材料的性能起反作用的氧气、水和其它化合物的进入。如果可挤出材料是光固化的胶液，那么储存器对于促进胶液固化的那些频率的光线必须是不透光的。
电磁能照源，优选使用高能激光器8，提供电磁能束9。
可挤出材料通过泵10由储存器进行输送，该泵优选由能精确控制的数字式电机驱动，以调节体系输送的可挤出材料的量。通过通道16将可挤出材料压入喷嘴的流径11。将光学窗12连接至喷嘴的一端，以闭合流径的一端。然而该窗对于能束9的频率是可以透射的，使能束9被直接导入流径，并与可挤出材料接触。可以使光学窗12具有光学功能而形成能束。流径优选是锥形的，将形成的能束与锥形流径在同一角度会聚。直接将能束和可挤出材料导入共用的路径保证了施加用的材料接触点和重合，并保证了在能束和可挤出材料间持续足够时间的相互作用。
喷嘴包括出口13，可挤出材料和激光束通过此出口排出。出口14的构形确定可挤出材料珠粒15的大小和形状。应知道的是，通过可挤出材料和基材的吸收，激光束将在施用点处消失。
如果可挤出材料是光固化的胶液，那么必须仔细控制该材料在流径中的体积，以防止该胶液在喷嘴内固化。
根据本发明的该实施方案，可挤出材料1和激光束9穿过出口13，并被同时射到目的材料2上。为了便于这种同时的施用，可挤出材料的流径和激光束的光径是同轴的。这种布置不需要如通过使用反光镜在混合室内改变激光的光径。
在优选的实施方案中，通过数字式电机14在出口13的下面移动基材。这提供了容易的数字式电机14和泵10，优选通过微处理机的控制，以致使可挤出材料能沿基材以可以是直线或曲线的连续线，以及如点和划的间断线进行施用。使用数字式电机是十分有益的，这是因为其精确的控制使可挤出材料能以可控的部分进行施用。此外，可使用计算机或其它以微处理机为基础的系统，以使目的材料的移动与泵10的操作相一致，从而保证相对于目的材料以希望的量施用可挤出材料。
在优选的实施方案中，可挤出材料对于激光束的电磁能稍微能透射一点，因此激光束的能量在喷嘴的流径中未被完全吸收。选择激光和可挤出材料的性能，以致使可挤出材料吸收足够的激光能将可挤出材料加热至希望温度，另外还提供连续加热可挤出材料和在可挤出材料沉积后的基材的能量。例如，可使可挤出材料过热(过辐照)，以增强其渗入目的材料2。
图3图示说明了本发明的一个实施方案，其中使用表面施用可挤出材料来进行粘合。将两片目的材料2对准，其间有一优选小于可挤出材料珠粒15的宽度的缝隙。出口13沿缝隙17移动，从而将激光束和可挤出材料导引至两片材上，以形成连续的接缝18。同时施加激光束能和可挤出材料，使可挤出材料能渗入两片目的材料的内部结构中。因此，在缝隙以外，可挤出材料还渗入目的材料2中，这将形成平滑且牢固的对接粘合。这将提供出具有单一目的片材的外观和性能的接缝。
图4图示说明了整个搭接的边对边对准的两片目的材料2的对接焊接，对接粘合在两片材的侧面上形成。接缝18沿缝隙17形成，从而将两片材固定在一起。沿缝隙应用少量软质可挤出材料，在已形成粘合后，将使相对于接缝的目的片材的移动不受制约。
图5图示说明了沿两目的片材的内部连接线将两片材进行对接焊接。出口13置于小于可挤出材料珠粒15尺寸的缝隙17的上方。该工艺使两目的材料间的粘合线在目的材料的内部形成。
应明白的是，因为通常不要求有任何可挤出材料流入该间隙，所以图3-5中所示的间隙17的尺寸可以是相对小的。而使可挤出材料被迫直接渗入其上粘合有珠粒的目的材料中。还应明白的是，在单一应用中可以组合如图3-5中所示的不同类型的对接粘合。例如，可以将一片目的片材的外侧边缘粘合至另一片材上的内粘合线上。
此外，在图3-7中所示的本发明的工艺还可以用来粘合不同成份的材料，只要每个要被粘合在一起的材料都易于表面施用可挤出材料。图6图示说明了根据本发明的方法将一片多孔目的材料21粘合至第二材料19上。将取自出口13的可挤出材料沉积在多孔目的材料上，并同时通过激光束进行辐照，以使可挤出材料如20处所示渗入多孔材料，并与第二片材19接触，因此在两片材间形成了牢固和连续的粘合。当目的材料在出口下面移动时，在材料19和21之间形成了牢固和连续的接缝18。
根据图6的实施方案，可以彼此成层铺设许多多孔材料，以致使可挤出材料渗入每一层中，并使之与相邻层粘合。因此，利用可挤出材料，可以将许多多孔层粘合成单一结构。
所附权利要求的范围内对本发明进行改进，这对本领域技术热练人员将是显而易见的。

Claims (21)

1.一种将可热活化的聚合物组合物施用于基材上的方法，该方法包括将所述的组合物以液态供至将所述组合物分散在所述基材上的流径中，并同时用能束辐照在所述流径中的所述组合物，其中所述的能束被定形成与所述流径相同的形状，并直接导入所说流径中的所述组合物中，从而将所述能束的能量传递至所述的组合物上，并且在所述组合物施用至基材上之后将能量传递到该基材上，以加热该基材。
2.根据权利要求1的方法，其中所述的组合物是可挤出的介质。
3.根据权利要求1的方法，其中所述的能束是激光。
4.一种将可热活化的聚合物组合物施用于基材上的装置，该装置包括形成流径的设备，该设备用来接收液态的所述组合物并用来沿所述的流径将所述的组合物导引至所述的基材上；以及另一设备，该设备用来将能束定形成与所述流径相同的形状，并将所述能束直接导入所述流径内的所述组合物中并导引至所述基材上，以辐照在所述流径中的所述的组合物，从而将所述能束的能量传递至所述的组合物上，并在所述组合物施用于所述基材上之后用所述能束辐照所述的基材。
5.根据权利要求4的装置，其中所述的形成流径的设备有一喷嘴。
6.根据权利要求5的装置，其中所述的喷嘴含有在横截方向上向所述流径提供所述组合物的设备和与所述流径对准用来将所述能量透射入所述流径内的光学窗。
7.根据权利要求5的装置，其中所述的流径是锥形的，并且还含有将所述能束沿所述流径聚集的设备。
8.根据权利要求7的装置，其中所述的用于聚集的设备含有与所述流径对准的光学窗。
9.根据权利要求6的装置，还含有支撑所述喷嘴的可拆卸设备。
10.根据权利要求6的装置，还含有将所述组合物以液态供至所述流径的连接所述喷嘴的设备。
11.根据权利要求10的装置，其中所述的组合物是热熔粘合剂，所述能束是激光束。
12.根据权利要求11的装置，其中所述的供料设备含有熔融所述组合物的加热器，以及将所述熔融的组合物供至所述喷嘴的泵。
13.根据权利要求12的装置，其中所述的储存器，加热器和泵紧密地连接所述的喷嘴。
14.根据权利要求13的装置，还含有根据预定的型式相对于所述喷嘴移动所述基材的设备。
15.根据权利要求4的装置，其中所述的形成流径的设备含有特所述能束透射至所述流径内的光学窗。
16.根据权利要求11的装置，其中所述的激光器是钇铝石榴石激光器。
17.根据权利要求16的装置，其中所述的热熔粘合剂是尼龙。
18.一种根据权利要求1的方法制得的制品。
19.根据权利要求18的制品，包含通过所述组合物粘合在一起的两个片材。
20.根据权利要求19的制品，其中所述的两个片材是对接粘合的。
21.根据权利要求19的制品，其中所述的两个片材是搭接粘合的。
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