Vibration welding of components with angled areas in the direction of vibration

Abstract

Conventional manufacturing processes for plastic products, such as injection molding or extrusion, often limit the achievable component geometries. Therefore, it is necessary to join components in order to generate highly complex geometries. Vibration welding is one way of joining components. This process is frequently used and is characterized by short cycle times, high energy efficiency, and the possibility of joining large components. In vibration welding, plastic components are heated by an oscillating friction movement of the joining surfaces, then plasticized and subsequently welded together. The joining of three-dimensional seam geometries is therefore a challenge for vibration welding, as the components can be lifted off by the linear movement and the surfaces do not plasticize sufficiently. Previous investigations have shown that angles of up to 20° can be welded in the direction of vibration, but that the deviation from the plane considerably reduces the weld strength. In order to weld three-dimensional weld seam geometries with short cycle times and simultaneously achieve a high weld seam strength, a process is being developed which is intended to extend the design freedom in vibration welding.