CN111136924A - 用于连接面板的混合超声铆接工艺 - Google Patents
用于连接面板的混合超声铆接工艺 Download PDFInfo
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- CN111136924A CN111136924A CN201910430167.4A CN201910430167A CN111136924A CN 111136924 A CN111136924 A CN 111136924A CN 201910430167 A CN201910430167 A CN 201910430167A CN 111136924 A CN111136924 A CN 111136924A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/72—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by combined operations or combined techniques, e.g. welding and stitching
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
- B29C65/7802—Positioning the parts to be joined, e.g. aligning, indexing or centring
- B29C65/782—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the gap between the parts to be joined
- B29C65/7823—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the gap between the parts to be joined by using distance pieces, i.e. by using spacers positioned between the parts to be joined and forming a part of the joint
- B29C65/7829—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the gap between the parts to be joined by using distance pieces, i.e. by using spacers positioned between the parts to be joined and forming a part of the joint said distance pieces being integral with at least one of the parts to be joined
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- B—PERFORMING OPERATIONS; TRANSPORTING
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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
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- 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
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- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
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- B29C65/607—Riveting or staking the rivets being integral with one of the parts to be joined, i.e. staking the integral rivets being hollow
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- B29C65/82—Testing the joint
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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
- B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
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- B29C66/0242—Heating, or preheating, e.g. drying
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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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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/01—General aspects dealing with the joint area or with the area to be joined
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
- B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
- B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
- B29C66/81427—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
- B29C66/81429—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth comprising a single tooth
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
- B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
- B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
- B29C66/81431—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single cavity, e.g. a groove
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
- B29C66/832—Reciprocating joining or pressing tools
- B29C66/8322—Joining or pressing tools reciprocating along one axis
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/90—Measuring or controlling the joining process
- B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
- B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2055/00—Use of specific polymers obtained by polymerisation reactions only involving carbon-to-carbon unsaturated bonds, not provided for in a single one of main groups B29K2023/00 - B29K2049/00, e.g. having a vinyl group, as moulding material
- B29K2055/02—ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3005—Body finishings
- B29L2031/3041—Trim panels
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Health & Medical Sciences (AREA)
- Toxicology (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Chemical & Material Sciences (AREA)
- Crystallography & Structural Chemistry (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
- Pressure Welding/Diffusion-Bonding (AREA)
Abstract
一种连接两个面板的装置,包括:腔室;位于所述腔室内的焊头,其中所述焊头在所述腔室内往复移动;以及定位在焊头周围以加热焊头的一组加热元件。其中一个面板具有模制在其上的支柱,所述支柱延伸穿过另一个面板,并且在加热所述焊头后,将所述焊头一端放在所述支柱顶部且进行超声波振动,以形成连接所述两个面板的支柱头部。
Description
技术领域
本公开涉及一种连接两个面板的装置。更具体地,本公开涉及一种采用超声铆接连接两个面板的装置。
背景技术
在典型机动车辆中,机动车辆包括诸如门等部件,这些部件具有内子部件和外子部件。在某些设置中,利用超声铆接装置将部件与聚合物支柱夹在一起。虽然目前连接面板的工艺实现了预期目的,但仍需要一种改进的新型装置和方法,用于将各种机动车辆部件中的面板连接在一起。
发明内容
根据若干方面,一种连接两个面板的装置包括:腔室;焊头,其位于腔室内且在腔室内往复移动;和一组加热元件,其围绕焊头定位以加热焊头。其中一个面板具有模制到其上的支柱,所述支柱延伸穿过另一个面板,且加热所述焊头后,将所述焊头一端放在所述支柱顶部并进行超声波振动以形成所述支柱头部,以便连接所述两个面板。
在本公开的另一方面,支柱由一种材料制成,材料的一部分流入支柱内部,增大支柱的拉拔强度。
在本发明的另一方面,在焊头(horn)超声波振动前和振动时,对腔室进行抽真空。
在本公开的另一方面,停止抽真空。
在本发明的另一方面,所述抽真空除去氧气,以避免材料热氧化。
在本公开的另一方面,超声波振动停止后,焊头将力施加至支柱头部。
在本公开的另一方面,在焊头向支柱的头部施加力时,将冷却空气流施加到焊头,所述冷却空气流的温度低于腔室的内部温度。
在本公开的另一方面,停止冷却空气流,且焊头向上移动远离支柱头部。
在本公开的另一方面,支柱由聚合物制成,对聚合物的冷却提高了聚合物结晶度。
根据若干方面,一种连接两个面板的装置包括:腔室;位于腔室内的焊头,其中焊头在腔室内往复移动;以及围绕焊头定位以加热焊头的一组加热元件。其中一个面板具有模制到其上的支柱,支柱延伸穿过另一个面板;支柱由一种材料制成,且一部分材料流入支柱内部以提高支柱拉拔强度。焊头加热后,将焊头一端放在支柱顶部并进行超声波振动以形成支柱头部,以便连接两个面板,且在焊头进行超声波振动之前和超声波振动期间,对腔室进行抽真空。
在本公开的另一方面,停止抽真空。
在本公开的另一方面,停止超声波振动后,焊头将力施加至支柱头部。
在本公开的另一方面,在焊头向支柱的头部施加力时,将冷却空气流施加到焊头,所述冷却空气流的温度低于腔室的内部温度。
在本公开的另一方面,停止冷却空气流,且焊头向上移动远离支柱头部。
根据若干方面,一种连接两个面板的方法包括以下一个或多个步骤:铆接面板,其中一个面板具有垫片,所述垫片具有模制在其上并延伸穿过另一个面板的支柱,支柱由一种材料制成,一部分材料流入支柱内部以提高支柱的拉拔强度;将面板夹在一起;加热位于腔室中的焊头;将焊头一端放在支柱顶部;并且对焊头实施超声波振动,以形成支柱头部。
在本公开的另一方面,所述方法包括在焊头超声波振动前和振动时,对腔室进行抽真空。
在本公开的另一方面,该方法还包括停止抽真空。
在本公开的另一方面,该方法还包括在停止超声波振动后,在支柱头部用焊头一端,将力施加至支柱头部。
在本公开的另一方面,该方法进一步包括,在焊头向支柱的头部施加力时,将冷却空气流施加到焊头,所述冷却空气流的温度低于腔室的内部温度。
在本公开的另一方面,该方法进一步包括,停止冷却空气流,且焊头向上移动远离支柱头部。
根据本文提供的描述,其他适用领域将变得显而易见。应该理解的是,描述和具体示例仅用于说明的目的,并不旨在限制本公开的范围。
附图说明
本文描述的附图仅用于说明目的,并不旨在以任何方式限制本公开的范围。
图1A-1D示出了根据示例性实施例的用于连接两个面板的装置;
图2是利用该装置的流程图;
图3示出了连接两个面板的支柱在抗拉强度方面的改进;以及
图4示出了说明利用图1A-1D中所示的装置形成的支柱增大的抗拉强度的曲线图。
具体实施方式
以下描述本质上仅是示例性的,并不旨在限制本公开、其应用或用途。
参照图1A至1D,示出了利用混合超声铆接工艺连接两个面板20和22的装置10。装置10包括腔室12和超声波发生器,例如位于腔室12中的焊头14。一组加热元件15围绕焊头14定位在腔室12中。腔16位于焊头14的末端。腔16的形状可以是具有任何合适横截面的任何合适形状。例如,在一些设置中,腔16是具有半球形横截面的圆环。在其他设置中,腔16具有花环形状,并且在某些设置中,腔16具有圆顶形状。
进一步参考图2以及图1A至1D,示出了实现装置10将两个面板20和22连接在一起的工艺100。在步骤102中,将面板放在嵌套中。具有桩或支柱18的垫片17首先模制到面板22上,且支柱18延伸穿过面板20。在步骤104中,将面板20和22夹在一起抵靠嵌套。支柱18由聚合物制成并且成形为具有内部区域21的管。
然后,工艺100转到步骤106,其中激活加热元件15,以利用热流Q加热焊头14以及支柱18。在步骤108中,对腔室12抽真空。在步骤110中,焊头14向下移动,使得焊头14端部与支柱18接合。用焊头14,将力Fo施加到支柱18。采用波形δ(t)振动焊头14(图1B),其中ω是频率,t是时间。连续振动焊头14,直到在支柱18顶部形成头部19。然后在步骤112中停止振动焊头14,且在步骤114中停止抽真空。在各种设置中,在工艺100中的任一所需时间停止抽真空。例如,在特定设置中,在施加Fo和超声波振动之前,停止抽真空;而在其他设置中,在施加超声波振动和力Fo之后,停止抽真空。无论何时停止抽真空,通过抽真空从腔室12中抽出氧气,以避免制成支柱18的聚合物降解(即,热氧化)。在一些设置中,将诸如氮气或氩气的气体注入腔室12中,置换腔室12中的氧气以防止聚合物降解。
在步骤116中,保持焊接力Fo,同时在步骤118中将腔室12中的开口27的冷却空气流C施加至支柱18和支柱18的头部19(图1C)。冷却空气C的温度低于腔室12的内部温度。选择冷却空气C的温度使得以受控速率冷却聚合物,从而确保聚合物的所需结晶度。在某些设置中,力Fo是恒定的,而在其他设置中,力是变化的。例如,在特定设置中,以所需速率增加或减小力Fo。在步骤120中,停止冷却空气流,且在步骤122中将焊头14向上移动并远离支柱18的头部19。在步骤124结束工艺100。
在特定设置中,支柱18由非晶型聚合物(ABS)制成,而在其他设置中,支柱18由半结晶聚合物(TPO)制成。在某些设置中,所施加的真空V在约0.5×105到3×103帕斯卡之间,以将氧气从与聚合物支柱18的接触移除,避免发生可能断链,即聚合物氧化。在各种设置中,将支柱18加热到约45℃和210℃之间的温度,冷却空气流量约在20英尺3/小时和70英尺3/小时之间。在特定设置中,焊接力约在50至450N之间。
现参考图3,示出了在工艺100期间,加热各种温度时,由半结晶聚合物(TPO)制成的支柱18的抗拉强度(图示为302)。应注意的是,在各种设置中,当焊头14温度保持在特定温度时,首先加热聚合物,然后进行冷却以确保聚合物所需的结晶度。具体地,图3示出了由于焊头14加热支柱18而改善了支柱18的抗拉强度。因此,图3清楚地示出了,通过增大对支柱18的加热提高了支柱18的抗拉强度,改善了面板20和22之间的夹紧强度。在步骤118中冷却支柱18,这进一步增强了保持和设定支柱18的抗拉强度。
总之,装置10和工艺100引入热空气流,以便预热聚合物支柱18和焊头14,降低聚合物刚度,并在聚合物的超声摩擦加热期间提高聚合物流动。注意,对于混合超声铆接装置10和工艺100,一部分聚合物流入支柱18的内部区域21,形成材料塞29,如图4所示。然而,在形成例如支柱420的头部422的常规超声铆接工艺中,很少或无聚合物材料在支柱420的内部区域424中流动。如此,如拉拔强度(N)作为位移(mm)的函数的曲线图所示。作为示例,对于在约0.45mm和0.55mm之间的位移,根据本公开原理形成的支柱18(其具有头部19)的拉拔强度404比通过传统工艺程形成的支柱420(其具有头部422)的拉拔强度402大约大25%。因此,图4清楚地示出了材料29流入支柱18的内部区域21中,增大了具有头部19的支柱18的拉拔强度。此外,当将力施加到支柱18的头部19时,以选定速率冷却聚合物确保了所需的聚合物结晶度,从而当将两个面板20和22夹在一起时,进一步增强支柱18和头部19的抗拉强度。
利用本公开的混合超声波铆接装置10和工艺100,提供了一个或多个优点。包括预热聚合物以降低聚合物刚度的能力。预热聚合物以及聚合物超声波振动的摩擦加热提高了聚合物的抗拉强度,且冷却聚合物能够保持抗拉强度。
本公开的描述本质上仅是示例性的,并且不脱离本公开的主旨的变型旨在落入本公开的范围内。不应将这些变型视为脱离本公开的精神和范围。
Claims (9)
1.一种连接两个面板的装置,包括:
腔室;
焊头,其位于腔室内且在腔室内往复移动;和
一组加热元件,其围绕焊头定位以加热焊头;
其中一个面板具有模制到其上的支柱,所述支柱延伸穿过另一个面板,和
其中加热所述焊头后,将所述焊头一端放在所述支柱顶部并进行超声波振动以形成所述支柱头部,以便连接所述两个面板。
2.根据权利要求1所述的装置,其中,所述支柱由一种材料制成,所述材料的一部分流入所述支柱内部,以提高所述支柱的拉拔强度。
3.根据权利要求1所述的装置,其中,在所述焊头的超声波振动之前和期间,对所述腔室抽真空。
4.根据权利要求3所述的装置,其中,停止抽真空。
5.根据权利要求3所述的装置,其中,所述抽真空除去了氧气,以避免材料热氧化。
6.根据权利要求1所述的装置,其中,停止超声波振动后,所述焊头将力施加到所述支柱的头部。
7.根据权利要求6所述的装置,其中,在所述焊头向所述支柱的头部施加力时,将冷却空气流施加到所述焊头,所述冷却空气流的温度低于所述腔室的内部温度。
8.根据权利要求7所述的装置,其中,停止冷却空气流,并且将所述焊头向上移离所述支柱的头部。
9.根据权利要求7所述的装置,其中,所述支柱由聚合物制成,并且对所述聚合物的冷却提高了聚合物结晶度。
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CN111136924B (zh) | 2022-04-26 |
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