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CN111433278A - 激光焊接用接合材料和使用其的激光焊接方法 - Google Patents

激光焊接用接合材料和使用其的激光焊接方法 Download PDF

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Publication number
CN111433278A
CN111433278A CN201880078345.5A CN201880078345A CN111433278A CN 111433278 A CN111433278 A CN 111433278A CN 201880078345 A CN201880078345 A CN 201880078345A CN 111433278 A CN111433278 A CN 111433278A
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China
Prior art keywords
laser welding
laser
joining material
joining
ethylene
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Granted
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CN201880078345.5A
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CN111433278B (zh
Inventor
郑镇美
朴春缟
俞在贞
郑有珍
李承容
李秀珉
孙富源
辛富建
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LG Chem Ltd
LX Hausys Ltd
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LG Chem Ltd
LG Hausys Ltd
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
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    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/10—Homopolymers or copolymers of propene
    • C08L23/12—Polypropene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
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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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Abstract

本发明涉及激光焊接用结合构件，使用该激光焊接用结合构件的激光焊接方法，以及使用该激光焊接方法的激光结合体，其中，该结合构件包括：包含聚丙烯树脂的聚合物基质；以及针状无机填料。根据本发明的实施例的激光焊接用结合构件可以有效地与被焊接体激光焊接。

Description

激光焊接用接合材料和使用其的激光焊接方法
技术领域
本说明书要求于2017年12月7日向韩国知识产权局提交的韩国专利申请第10-2017-0167726号的优先权和权益，其全部内容通过引用并入本文。
本发明涉及一种激光焊接用接合材料、使用该接合材料的激光焊接方法以及通过使用该激光焊接方法制造的激光接合体。
背景技术
近来，在诸如运输装置(例如汽车)、电子产品和移动装置的各种工业领域中，为了减轻重量，部件的材料已经由塑料代替。此外，为了使这些塑料材料部件结合，已经尝试了各种方法。代表性的接合方法的示例包括使用诸如螺钉或铆钉的机械紧固件的方法、通过粘合剂的接合方法、振动焊接方法、超声焊接方法等。
在各种接合方法中，特别地，使用激光焊接塑料材料的方法由于相对简单的工艺而表现出与现有的其他接合方法等同或更高的效果。
然而，在塑料部件包括用于增强塑料材料的物理性能的诸如有机和无机填料的添加剂的情况下，存在如下问题，即这些添加剂由于在激光的传输过程中分散或吸收能量而大大降低了接合效率。此外，在塑料材料具有高结晶度的情况下，存在如下问题，即由于在激光的传输过程中散射或吸收能量，而降低和分散到达部件之间的界面的能量，从而降低了接合效率。
因此，需要开发一种用于塑料部件的材料，该材料能够通过使用激光进行焊接并且具有优异的机械性能。
[现有技术文献]
[专利文献]
韩国专利申请公开号：KR 10-2015-0116669 A
发明内容
技术问题
做出本发明用以解决由于塑料材料中包含的添加剂而降低激光焊接的接合效率的问题，并提供一种激光焊接用接合材料以及使用该接合材料的激光焊接方法，其中激光焊接用接合材料可以有效地实现与待接合材料的激光焊接。
然而，本发明要解决的问题不限于上述问题，并且本领域技术人员从以下描述中可以清楚地理解未提及的其他问题。
技术方案
本发明的示例性实施例提供了一种激光焊接用接合材料，该接合材料包含：聚合物基质，该聚合物基质包含在230℃的温度和2.16kg的载荷下测得的熔融指数为80g/10min以上且95g/10min以下的聚丙烯树脂；以及针状无机填料，该针状无机填料具有10:1至20:1的长宽比。
本发明的另一示例性实施例提供了一种激光焊接方法，该方法包括：制备激光焊接用接合材料；将激光焊接用接合材料和至少一部分待接合材料层压；以及在激光焊接用接合材料和待接合材料被层压的区域中照射激光以形成焊接区域，其中，将激光照射为穿过激光焊接用接合材料朝向待接合材料的表面。
本发明的又一示例性实施例提供了一种通过激光焊接方法制得的激光接合体。
有益效果
通过使用根据本发明的示例性实施例的激光焊接用接合材料制造的激光接合体具有优异的机械强度，因此可以用作各种仪器的部件。
根据本发明的示例性实施例的激光接合体具有弯曲模量和接合强度优异的优点。
根据本发明的示例性实施例的激光接合材料可以通过使在激光的照射期间能量的分散和/或内部散射最小化来有效地实现与待接合材料的激光焊接。
附图说明
图1是用于说明针状无机填料的外观的图。
图2示意性地示出了根据本发明示例性实施例的激光接合材料和在激光的照射工艺期间待接合材料的截面。
图3示出了根据本发明示例性实施例的激光焊接方法。
图4是无机填料(C1)的扫描电子显微镜(SEM)图像。
图5是无机填料(C2)的扫描电子显微镜(SEM)图像。
图6是无机填料(C3)的扫描电子显微镜(SEM)图像。
图7是无机填料(C4)的扫描电子显微镜(SEM)图像。
图8是无机填料(C5)的扫描电子显微镜(SEM)图像。
图9示出了在测量本发明的焊接强度时的激光接合体样本。
图10示出了用于测量本发明的激光接合体样本的焊接强度的方法。
具体实施方式
在整个说明书中，当一个构件被设置在另一构件“上”时，这不仅包括该一个构件与另一构件接触的情况，还包括在两个构件之间存在又一构件的情况。
在整个说明书中，当在整个说明书中一个部件“包括”一个构成要素时，除非另外具体说明，否则这并不意味着排除另一构成要素，而是意味着可以进一步包括另一构成要素。
在整个说明书中，“A和/或B”是指“A或B，或A和B”。
在整个说明书中，单位“重量份”可以指各个组分之间的重量比。
作为不断开发能够通过激光焊接方法接合至待接合材料的材料作为高强度塑料材料的结果，本发明人开发了以下发明。具体地，本发明人通过调节聚丙烯树脂的物理性能并调节针状无机填料的长宽比以实现高硬度物理性能，开发了优化的激光焊接用接合材料，并确认了如上所述的激光焊接用接合材料可以应用于各种产品。
在下文中，将更详细地描述本发明。
本发明的示例性实施例提供了一种激光焊接用接合材料，该接合材料包含：聚合物基质，该聚合物基质包含在230℃的温度和2.16kg的载荷下测得的熔融指数为80g/10min以上且95g/10min以下的聚丙烯树脂；以及针状无机填料，该针状无机填料的长宽比为10:1至20:1。
根据本发明的示例性实施例，对于激光焊接用接合材料，可以将针状无机填料分散在包含聚丙烯树脂的聚合物基质中。
激光焊接用接合材料可以具有优异的机械刚度和耐冲击性，因为针状无机填料适当地分散在聚合物基质中以增加激光焊接用接合材料的结晶度。此外，激光焊接用接合材料的优点在于，由于即使在较小的厚度下也可以实现优异的机械性能，因此激光焊接用接合材料可以应用于各种产品。
根据本发明的示例性实施例，聚丙烯树脂可以包括：丙烯均聚物、乙烯-丙烯共聚物、丙烯和具有4至10个碳原子的烯烃基单体的共聚物、以及聚丙烯和乙烯-丙烯橡胶的嵌段共聚物中的至少一种。具体地，聚丙烯树脂可以包括乙烯-丙烯共聚物。
根据本发明的示例性实施例，在乙烯-丙烯共聚物中，乙烯重复单元的含量可以为3wt％以上且10wt％以下。
由于乙烯-丙烯共聚物包含相对少量的乙烯重复单元，因此可以提高聚丙烯树脂的结晶度并改善激光焊接用接合材料的刚度和耐冲击性。
根据本发明的示例性实施例，聚丙烯树脂在230℃的温度和2.16kg的载荷下测得的熔融指数为80g/10min以上且95g/10min以下。
由于聚合物基质包含熔融指数在上述范围内的聚丙烯树脂，因此包含该聚合物基质的激光焊接用接合材料可以具有更高的成型性和外观特性，并且同时可以确保高机械刚度。具体地，当聚丙烯树脂的熔融指数小于上述范围时，由于注射成型期间树脂的流动性降低，因此可加工性可能劣化。此外，当聚丙烯树脂的熔融指数大于上述范围时，在注射成型期间树脂的流动性过大，使得包含聚合物基质的激光焊接用接合材料的刚度和耐冲击性之间的平衡降低，因此，机械性能可能降低。
根据本发明的示例性实施例，聚合物基质可以以40wt％以上且90wt％以下的量包含聚丙烯树脂。
当聚丙烯树脂的含量在上述范围内时，针状无机填料的浓度被适当地保持，从而可以防止由激光焊接用接合材料形成的产品的外观被针状无机填料改性，并可以有效地实现由针状无机填料引起的机械性能的提高。
根据本发明的示例性实施例，聚丙烯树脂的重均分子量可以为50000g/mol以上且500000g/mol以下。
当聚丙烯树脂的重均分子量在上述范围内时，优点在于，可以使激光焊接用接合材料的可加工性的劣化最小化，并且可以显著提高其机械性能。
根据本发明的示例性实施例，针状无机填料的长宽比为10:1至20:1。
通过在上述范围内调节针状无机填料的长宽比以使在激光焊接期间可能产生的能量的分散或反射最小化，可以通过激光照射形成激光焊接用接合材料的合适的熔池。
在针状无机填料的长宽比小于10:1或大于20:1的情况下，可能产生由于在激光照射期间激光在接合材料中被散射而导致到达与待接合材料的界面的激光束的区域变宽的结果。如上所述的结果可能导致激光焊接的强度降低，并且当将用于激光的接合材料用作产品的配置时，可能导致产品的可靠性下降。
另外，可以在上述范围内调节针状无机填料的长宽比以提高激光焊接用接合材料的机械刚度，并且可以将针状无机填料均匀地分散在聚合物基质中以实现激光焊接用接合材料的均匀的物理性能。
在本发明中，无机填料的长宽比可以是无机填料的平均长度相对于其平均宽度(平均直径)的值，即“平均长度/平均宽度”。
图1是用于说明针状无机填料的长宽比的图。具体地，针状无机填料的宽度(w)和针状无机填料的长度(l)与图1所示相同，并且可以通过利用宽度(w)和长度(l)来获得针状无机填料的长宽比。
在本发明中，可以通过以下方法来测量平均宽度和平均长度：通过扫描电子显微镜(SEM)拍摄针状无机填料，以放大倍率(其中一个最小的针状无机填料的尺寸为2mm至5mm)测量300至500个粒子的宽度和长度，并且得到其平均值。
此外，根据本发明的示例性实施例，针状无机填料可以具有约5μm至约10μm的平均宽度(平均直径)，并且可以具有约30μm至约40μm的平均长度。可以通过调节无机填料的平均宽度和平均长度来实现针状无机填料的适当形状。另外，当用激光照射激光焊接用接合材料时，可以使激光的散射最小化。
根据本发明的示例性实施例，针状无机填料可以包括氧硫酸镁基粒子、水合硅酸镁基粒子和硅酸钙基粒子中的至少一种。具体地，根据本发明的示例性实施例，针状无机填料可以包括作为硅酸钙基粒子的硅灰石粒子。
根据本发明的示例性实施例，基于100重量份的激光焊接用接合材料，针状无机填料的含量可以为5重量份以上且30重量份以下。具体地，基于100重量份的激光焊接用接合材料，针状无机填料的含量可以为8重量份以上且25重量份以下，10重量份以上且20重量份以下，或12重量份以上且16重量份以下。
当无机填料的含量在上述范围内时，可以在激光接合期间将激光焊接用接合材料有效地接合至待接合材料，并且此外，可以确保激光焊接用接合材料的机械刚度。
根据本发明的示例性实施例，聚合物基质可以进一步包含热塑性弹性体。
热塑性弹性体可以赋予激光焊接用接合材料耐冲击性和耐热性。
根据本发明的示例性实施例，热塑性弹性体可以包括乙烯和具有4至30个碳原子的α-烯烃的嵌段共聚物。
根据本发明的示例性实施例，具有4至30个碳原子的α-烯烃可以包括1-丁烯、1-戊烯、4-甲基-戊烯、1-己烯、1-庚烯、1-辛烯、1-癸烯、1-十一碳烯、1-十二碳烯、1-十四碳烯、1-十六碳烯和1-二十碳烯中的至少一种α-烯烃化合物。
根据本发明的示例性实施例，在乙烯和具有4至30个碳原子的α-烯烃的嵌段共聚物中，乙烯与α-烯烃的摩尔比可以为6:4至7:3。
根据本发明的示例性实施例，乙烯和具有4至30个碳原子的α-烯烃的嵌段共聚物可以包括乙烯-1-辛烯嵌段共聚物和乙烯-1-丁烯嵌段共聚物中的至少一种。
根据本发明的示例性实施例，热塑性弹性体在190℃的温度和2.16kg的载荷下测得的熔融指数可以为0.5g/10min以上且10g/10min以下。具体地，乙烯-1-辛烯嵌段共聚物在190℃的温度和2.16kg的载荷下测得的熔融指数可以为5g/10min以上且10g/10min以下。此外，乙烯-1-丁烯嵌段共聚物在190℃的温度和2.16kg的载荷下测得的熔融指数可以为0.5g/10min以上且3g/10min以下。由于热塑性弹性体的熔融指数在上述范围内，因此可以通过调节激光焊接用接合材料的熔融指数并且具有适当的流动性来实现优异的尺寸稳定性和高的耐冲击性。
根据本发明的示例性实施例，热塑性弹性体可以具有50000g/mol至180000g/mol的重均分子量。由于热塑性弹性体的重均分子量在上述范围内，因此热塑性弹性体具有优异的尺寸稳定性和高的耐冲击性，从而可以改善聚合物基质中包含的聚丙烯树脂的不足的物理性能。
根据本发明的示例性实施例，热塑性弹性体可以具有0.8g/cm3至0.9g/cm3的密度，具体地，具有0.86g/cm3至0.87g/cm3的密度。由于热塑性弹性体的密度在上述范围内，因此可以减轻激光焊接用接合材料的重量。
根据本发明的示例性实施例，基于100重量份的激光焊接用接合材料，热塑性弹性体的含量可以为5重量份以上且30重量份以下。
当热塑性弹性体的含量在上述范围内时，可以提高激光焊接用接合材料的耐冲击性和尺寸稳定性，并且同时防止在使用激光焊接用接合材料的激光焊接期间焊接效率降低。
根据本发明的示例性实施例，激光焊接用接合材料可以具有0.5mm以上且5mm以下的厚度。
当激光焊接用接合材料的厚度在上述范围内时，可以容易地进行在激光焊接用接合材料的制造期间的注入。此外，当激光焊接用接合材料具有在上述范围内的厚度时，在使用激光的焊接期间的透光率极低，从而可以防止不能确保焊接强度的情况。
根据本发明的示例性实施例，激光焊接用接合材料在980nm的波长处可以具有20％以上的透光率。具体地，激光焊接用接合材料在980nm的波长下的透光率可以为20％以上且50％以下，25％以上且50％以下，或者20％以上且40％以下，20％以上且30％以下，或者25％以上且30％以下。
激光焊接用接合材料的透光率可以具有与激光透射率相同的含义。此外，当激光焊接用接合材料具有在上述范围内的透光率时，在使用激光焊接用接合材料的激光焊接期间，激光可以有效地传递到待接合材料，因此，可以通过有效地形成熔池来实现高接合强度。
根据本发明的示例性实施例，由于激光焊接用接合材料的优异的刚度和耐冲击性，所以可以将激光焊接用接合材料用作构成产品的材料。具体地，激光焊接用接合材料可以是用于汽车室内材料(例如仪表板、车顶、门、座椅和后备箱)的材料。然而，激光焊接用接合材料不限于此，并且可以用作用于各种电子设备的部件、壳体等的材料。
本发明的另一示例性实施例提供了一种激光焊接方法，该方法包括：制备激光焊接用接合材料；将激光焊接用接合材料和至少一部分待接合材料层压；以及在激光焊接用接合材料和待接合材料被层压的区域中照射激光以形成焊接区域，其中，将激光照射为穿过激光焊接用接合材料朝向待接合材料的表面。
图2示意性地示出了根据本发明示例性实施例的激光接合材料和在激光的照射过程期间待接合材料的截面。具体地，图2示出了激光焊接用接合材料100和待接合材料200彼此层压，并通过激光照射进行激光焊接。在图2中，激光焊接用接合材料100中的条形表示针状无机填料，a表示焊接宽度，b表示熔池区域。
根据本发明的示例性实施例，待接合材料可以是在980nm的波长下具有80％以上的光吸收率的塑料构件。即，待接合材料是塑料构件，并且可以吸收波长为980nm的光的80％以上。
作为待接合材料的塑料构件可以是与上述用于激光焊接的材料相同的材料。具体地，作为待接合材料的塑料构件可以包括：丙烯均聚物、乙烯-丙烯共聚物、丙烯和具有4至10个碳原子的烯烃基单体的共聚物、以及聚丙烯和乙烯-丙烯橡胶的嵌段共聚物中的至少一种。此外，如果需要，待接合材料可以包括诸如染料和/或颜料的着色剂，以增加光吸收率。
根据本发明的示例性实施例，激光的总线能量值为1.5J/mm以上且3J/mm以下，并且总线能量可以由以下等式1定义。
[等式1]
Etot＝P/v×重复次数
在等式1中，Etot表示总线能量(J/mm)，P表示激光功率(W)，并且v表示激光照射率(mm/s)。
根据本发明的示例性实施例，总线能量值可以为1.5J/mm以上且3.0J/mm以下。
当在总线能量值范围内照射激光时，可以使激光照射的重复次数优化从而缩短处理时间并实现优异的附接力。
根据本发明的示例性实施例，激光的波长可以是800nm至1200nm中的任一波长值。具体地，激光的波长可以是980nm。
根据本发明的示例性实施例，激光的输出可以是50W以上且2000W以下，并且具体地，可以是50W以上且100W以下，或55W以上且70W以下。激光的输出可以根据激光的光斑尺寸和待接合材料的类型适当地调节。
根据本发明的示例性实施例，激光的光斑尺寸可以是100μm至5000μm，并且可以根据待接合材料的类型适当地调节。
根据本发明的示例性实施例，激光的照射率可以是10mm/s以上且1000mm/s以下，具体地是30mm/s以上且300mm/s以下，或50mm/s以上且200mm/s以下，并且可以根据待接合材料的类型适当地调节。
根据本发明的示例性实施例，激光的重复次数可以是1次至50次，具体地是1次至10次，3次至7次，或4次至7次，并且可以根据激光所照射材料的类型适当地调节。
根据本发明的示例性实施例，焊接步骤为激光透射接合方法，并且可以通过聚焦于激光焊接用接合材料与待接合材料之间的界面上，而沿待接合材料的方向用激光来照射激光焊接用接合材料。
图3示出了根据本发明示例性实施例的激光焊接方法。具体地，图3示出了通过聚焦于激光焊接用接合材料100与待接合材料200之间的界面上，而沿待接合材料200的方向用激光来照射激光焊接用接合材料100，从而形成焊接区域300。
根据本发明的示例性实施例，激光焊接用接合材料可以在980nm的波长下具有20％以上且50％以下，25％以上且40％以下，或25％以上且35％以下的激光透射率。在该激光透射率范围内，使用激光焊接用接合材料可以在激光焊接期间实现优异的附接力。
本发明的示例性实施例提供了一种通过激光焊接方法制造的激光接合体。激光接合体可以指通过使用激光焊接将激光焊接用接合材料和待接合材料接合。
激光接合体可以是汽车内饰材料或电子设备的一部分。
[发明方式]
在下文中，将参考用于具体描述本发明的示例详细描述本发明。然而，根据本发明的示例可以以各种形式修改，并且不被解释为将本发明的范围限于以下描述的示例。提供本发明的示例是为了向本领域普通技术人员更完整地解释本发明。
[示例1]
将在230℃的温度和2.16kg的载荷下测得的具有7wt％的乙烯重复单元含量和90g/10min的熔融指数的乙烯-丙烯共聚物(A1)，在190℃的温度和2.16kg的载荷下测得的具有7.5g/10min的熔融指数的乙烯-1-辛烯嵌段共聚物(B1)，在190℃的温度和2.16kg的载荷下测得的具有1.75g/10min的熔融指数的乙烯-1-丁烯嵌段共聚物(B2)，以及下表1中的针状无机填料(C1)，以下表2中示出的含量混合。下表2中的含量单位为重量份。
此外，通过在200℃至240℃下使用双螺杆挤出机挤出混合物来制造厚度为1.5mm的激光焊接用接合材料。
[示例2和实例3以及比较例1至比较例4]
以与示例1中相同的方式制造激光焊接用接合材料，不同之处在于，使用了下表1中的每种无机填料，并且以下表2中的含量使混合物混合。
[比较例5和比较例6]
以与示例1中相同的方式制造激光焊接用接合材料，不同之处在于，在比较例5和比较例6中分别使用了在230℃的温度和2.16kg的载荷下测得的具有10g/10min的熔融指数的乙烯-丙烯共聚物(A2)和在230℃的温度和2.16kg的载荷下测得的具有130g/10min的熔融指数的乙烯-丙烯共聚物(A3)，并且以下表2中的含量使混合物混合。
图4至图8分别是无机填料(C1)至无机填料(C5)的扫描电子显微镜(SEM)图像。
通过SEM图像，测量了无机填料(C1)至无机填料(C5)的长宽比，并且其结果被一起示于下表1中。
[表1]
Figure BDA0002523002790000101
Figure BDA0002523002790000111
[表2]
Figure BDA0002523002790000112
之后，通过以下方法测量示例1至示例3以及比较例1至比较例6的激光焊接用接合材料的物理性能。
抗拉强度的测量
制造厚度为6.4mm的样本，并通过使用抗拉强度试验机向样本的两端施加力以50mm/min的速率测量抗拉强度。
弯曲模量和弯曲强度的测量
根据ASTM D790，制造厚度为6.4mm的样本，并通过向样本的中心施加力以10mm/min的速率测量弯曲模量和弯曲强度。
激光透射率的测量
通过使用UV-Vis-NIR(紫外光-可见光-近红外光)分光仪(Solid spec)在各波长下测量对样本的透射率。在这种情况下，激光透射率可以被计算为所测得的穿过样本的激光的输出相对于所使用的激光波长的输出值的比率，并且可以通过相同的方法来测量980nm处的透射率。
下表3示出了根据示例1至示例3以及比较例1至比较例6的激光结合用接合材料的物理性能。
[表3]
Figure BDA0002523002790000113
Figure BDA0002523002790000121
根据表3，可以确认，在示例1至示例3中，抗拉强度、弯曲模量和弯曲强度具有适用于激光接合体的抗拉强度、弯曲模量和弯曲强度，在比较例1至比较例6中也是。即，当以示例1至示例3中每一者的含量制造激光焊接用接合材料时，可以在不削弱抗拉强度、弯曲模量和弯曲强度的情况下提高激光焊接期间的焊接强度。
此外，激光透射率对应于根据无机填料而变化的物理性能，并且在具有适当水平的激光透射率的情况下，可以在不削弱激光焊接用接合材料的物理性能的情况下提高激光焊接的焊接强度。
冲击强度的测量
根据ASTM D256方法，通过用于硬质塑料的悬臂梁冲击试验机(悬臂梁的测量，日本东洋精机有限公司)来测量示例1以及比较例5和比较例6中激光焊接用接合材料的冲击强度。
样本的尺寸为64mm×12.5mm×6.36mm，通过使用开槽机形成25.4mm的切口，然后测量冲击强度，其结果示于下表4中。
[表4]
Figure BDA0002523002790000122
如表4中所示，可以看出，激光焊接用接合材料的冲击强度根据聚丙烯树脂的熔融指数而变化。
具体地，可以看出，聚丙烯树脂的熔融指数为10g/10min的比较例5不具有适合用作激光焊接用接合材料的物理性能，因为与表3中的示例1至示例3相比，冲击强度迅速增加，但是弯曲模量降低。此外，可以看出，聚丙烯树脂的熔融指数为130g/10min的比较例6不具有适合用作激光焊接用接合材料的物理性能，因为弯曲模量与示例1至示例3的弯曲模量相似，但是冲击强度降低。
之后，进行以下实验，以便测量根据无机填料的类型的激光焊接的焊接强度以及根据聚丙烯树脂的熔融指数的激光焊接的焊接强度。
焊接强度的测量
制造与示例1具有相同组成并且包含基于总重量含量为0.3重量份的炭黑的待接合材料。
在将根据示例1至示例3以及比较例1和比较例4制造的每种激光焊接用接合材料放置在待接合材料上之后，通过使用夹具将激光焊接用接合材料固定。此外，通过使用二极管激光(ELED-100RD)进行激光焊接来制造激光接合体。激光的上限输出、激光波长和正焦尺寸分别为110W、980nm和1.6mm。
图9示出了在焊接强度的测量期间的激光接合体样本。具体地，图9示出了在将待接合材料200上的部分区域与所制造的激光焊接用接合材料100层压之后，通过激光照射形成并接合焊接区域300。
将激光焊接条件设定为总线能量为1.8J/mm(条件：输出功率为80W，照射率为180mm/s，重复次数为4次)，测量相应的焊接强度(附接力)，并在下表5中示出。
图10示出了测量激光接合体样本的焊接强度。可以通过使用抗拉强度试验机来测量焊接强度，具体地，测量当通过以10mm/min的速率拉伸所制造的激光接合体来使激光焊接用接合材料和待接合材料分离时的力。
[表5]
Figure BDA0002523002790000131
如表5中所示，可以看出，与使用根据比较例1至比较例4的其中无机填料的长宽比在上述范围以外的激光焊接用接合材料的激光接合体相比，使用示例1至示例3中的包括长宽比为10:1至20:1的针状无机填料的激光焊接用接合材料的激光接合体表现出优异的焊接强度。可以看出，由于在比较例1至比较例4中激光焊接用接合材料中包含的无机填料，激光透射率在适当范围之外，结果，降低了激光接合体的焊接强度。
此外，除了将总线能量设定为1.5J/mm(条件：输出功率为60W，照射率为40mm/s，重复次数为1次)之外，以与测量焊接强度的过程相同的方式将示例1以及比较例5和比较例6中的激光焊接用接合材料和待接合材料进行激光焊接，测量相应的焊接强度，并且其结果示于下表6中。
[表6]
示例1 比较例5 比较例6
焊接强度(MPa) 12.88 10.26 9.6
根据表6，可以确认，与使用比较例5和比较例6中的激光焊接用接合材料的激光接合体相比，使用示例1中的激光焊接用接合材料的激光接合体具有更高的焊接强度。因此，可以看出，根据本发明示例性实施例的示例1中的激光焊接用接合材料在具有激光焊接用接合材料所需的合适的物理性能的同时还提高了焊接强度。
因此，可以确认，根据本发明示例性实施例的激光焊接用接合材料确保了适合用作激光焊接用接合材料的抗拉强度、弯曲模量、弯曲强度和冲击强度，并提高了激光焊接期间激光接合体的焊接强度。
[附图标记和符号的说明]
100：激光焊接用接合材料
200：待接合材料
300：焊接区域

Claims (14)

1.一种激光焊接用接合材料，包括：
聚合物基质，所述聚合物基质包含在230℃的温度和2.16kg的载荷下测得的熔融指数为80g/10min以上且95g/10min以下的聚丙烯树脂；以及
针状无机填料，所述针状无机填料具有10:1至20:1的长宽比。
2.根据权利要求1所述的接合材料，其中，所述聚丙烯树脂包括：丙烯均聚物、乙烯-丙烯共聚物、丙烯和具有4至10个碳原子的烯烃基单体的共聚物、以及聚丙烯和乙烯-丙烯橡胶的嵌段共聚物中的至少一种。
3.根据权利要求2所述的接合材料，其中，在所述乙烯-丙烯共聚物中，乙烯重复单元的含量为3wt％以上且10wt％以下。
4.根据权利要求1所述的接合材料，其中，基于100重量份的所述激光焊接用接合材料，所述针状无机填料的含量为5重量份以上且30重量份以下。
5.根据权利要求1所述的接合材料，其中，所述聚合物基质进一步包含热塑性弹性体。
6.根据权利要求5所述的接合材料，其中，所述热塑性弹性体在190℃的温度和2.16kg的载荷下测得的熔融指数为0.5g/10min以上且10g/10min以下。
7.根据权利要求5所述的接合材料，其中，所述热塑性弹性体包括乙烯和具有4至30个碳原子的α-烯烃的嵌段共聚物。
8.根据权利要求7所述的接合材料，其中，在乙烯和具有4至30个碳原子的α-烯烃的所述嵌段共聚物中，所述乙烯与所述α-烯烃的摩尔比为6:4至7:3。
9.根据权利要求5所述的接合材料，其中，基于100重量份的所述激光焊接用接合材料，所述热塑性弹性体的含量为5重量份以上且30重量份以下。
10.根据权利要求1所述的接合材料，其中，所述激光焊接用接合材料的厚度为0.5mm以上且5mm以下。
11.根据权利要求1所述的接合材料，其中，所述激光焊接用接合材料在980nm的波长处具有20％以上的透光率。
12.一种激光焊接方法，包括：
制备根据权利要求1所述的激光焊接用接合材料；
将所述激光焊接用接合材料和至少一部分待接合材料层压；以及
在所述激光焊接用接合材料和所述待接合材料被层压的区域中照射激光，以形成焊接区域，
其中，将所述激光照射为穿过所述激光焊接用接合材料朝向所述待接合材料的表面。
13.根据权利要求12所述的方法，其中，所述激光的总线能量值为1.5J/mm以上且3J/mm以下，并且所述总线能量由以下等式1定义：
[等式1]
Etot＝P/v×重复次数
在等式1中，Etot表示总线能量(J/mm)，P表示激光功率(W)，并且v表示激光照射率(mm/s)。
14.一种通过使用根据权利要求12所述的激光焊接方法制得的激光接合体。
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