CN102834661A - 通气构件及其制造方法 - Google Patents

通气构件及其制造方法 Download PDF

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CN102834661A
CN102834661A CN2011800148094A CN201180014809A CN102834661A CN 102834661 A CN102834661 A CN 102834661A CN 2011800148094 A CN2011800148094 A CN 2011800148094A CN 201180014809 A CN201180014809 A CN 201180014809A CN 102834661 A CN102834661 A CN 102834661A
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supporting mass
cover cap
laser
air ventilation
ventilation membrane
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植村高
矢野阳三
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Nitto Denko Corp
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Nitto Denko Corp
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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
    • B29C66/812—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 composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/8126—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 composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/81266—Optical properties, e.g. transparency, reflectivity
    • B29C66/81267—Transparent to electromagnetic radiation, e.g. to visible light
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
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    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
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    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
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    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B29C66/541—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles a substantially flat extra element being placed between and clamped by the joined hollow-preforms
    • B29C66/5412—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles a substantially flat extra element being placed between and clamped by the joined hollow-preforms said substantially flat extra element being flexible, e.g. a membrane
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    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/727—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being porous, e.g. foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S45/00—Arrangements within vehicle lighting devices specially adapted for vehicle exteriors, for purposes other than emission or distribution of light
    • F21S45/30—Ventilation or drainage of lighting devices
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K5/00—Casings, cabinets or drawers for electric apparatus
    • H05K5/02—Details
    • H05K5/0213—Venting apertures; Constructional details thereof
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K5/00—Casings, cabinets or drawers for electric apparatus
    • H05K5/02—Details
    • H05K5/0213—Venting apertures; Constructional details thereof
    • H05K5/0216—Venting plugs comprising semi-permeable membranes
    • 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
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1603—Laser beams characterised by the type of electromagnetic radiation
    • B29C65/1612—Infrared [IR] radiation, e.g. by infrared lasers
    • B29C65/1616—Near infrared radiation [NIR], e.g. by YAG lasers
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/58—Snap connection
    • 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
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
    • B29C66/474—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially non-flat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • 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
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B29C66/712—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined the composition of one of the parts to be joined being different from the composition of the other part
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7394—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/812—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 composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
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Abstract

通气构件（10）具备：支承体（4），其具有壳体（20）的内部空间（22）与外部空间（24）之间的通气路径（3）（通气孔（3））；通气膜（2），其配置在支承体（4）上，且在外部空间（24）侧将通气路径（3）密闭；罩盖（6），其安装于支承体（4），以保护通气膜（2）；及激光熔敷部（12），其将罩盖（6）与支承体（4）接合。例如，支承体（4）由相对容易吸收用于形成激光熔敷部（12）的激光的第一材料制成。罩盖（6）由比第一材料难以吸收激光且能使激光透过的第二材料制成。

Description

通气构件及其制造方法
技术领域
本发明涉及一种通气构件及其制造方法。
背景技术
在对灯、电动机、传感器、开关、ECU（electronic control unit：电子控制单元）等的汽车的电装部件进行收容的壳体安装有通气构件。通气构件确保壳体的内部与外部的通气并防止基于压力变化的不良情况，并阻止异物向壳体的内部的侵入。这种通气构件的例子在专利文献1及2中有公开。专利文献1公开的通气构件如图9所示。
通气构件101具备：支承体103；配置在支承体103上的通气膜102；及覆盖通气膜102的罩盖104。经由O型环105而在壳体106的开口部107固定有通气构件101。为了使通气构件101不从壳体106脱落而将支承体103的腿部108与开口部107卡合。罩盖104具备多个爪部104a。爪部104a与支承体103的外周部卡合，由此，将罩盖104固定于支承体103。
【在先技术文献】
【专利文献】
【专利文献1】日本特开2004-47425号公报
【专利文献2】日本特开2007-141629号公报
发明内容
近年来，随着汽车的部件的小型化及薄型化的进展，而要求简单且容易生产的通气构件。
即，本发明提供一种通气构件，能够安装于具有通气用的开口部的壳体，其具备：
支承体，其具有所述壳体的内部空间与外部空间之间的通气路径；
通气膜，其配置在所述支承体上，且在所述外部空间侧将所述通气路径密闭；
罩盖，其安装于所述支承体以保护所述通气膜；及
激光熔敷部，其将所述罩盖与所述支承体接合。
另一方面，本发明提供一种通气构件的制造方法，制造能够安装于具有通气用的开口部的壳体上的通气构件，所述通气构件的制造方法包括如下工序：
准备如下所述支承体、通气膜、罩盖的工序，该支承体具有所述壳体的内部空间与外部空间之间的通气路径，该通气膜在所述外部空间侧将所述通气路径密闭，该罩盖应安装于所述支承体上以保护所述通气膜；
相对于所述支承体而将所述通气膜及所述罩盖分别配置在规定的位置上的工序；及
向由所述支承体、所述通气膜及所述罩盖构成的组装体照射所述激光的工序，以通过透过了所述罩盖的激光使所述支承体的一部分熔化或透过了所述支承体的所述激光使所述罩盖的一部分熔化来形成将所述罩盖与所述支承体接合的激光熔敷部。
【发明效果】
根据本发明，利用激光熔敷部将罩盖与支承体接合。因此，允许省略用于将罩盖固定于支承体的卡合部等结构。因此，根据本发明，能够提供一种比以往简单的结构的通气构件。当然，也可以设置卡合部等结构。另外，由于利用激光熔敷来形成罩盖与支承体之间的接合部，也容易实现通气构件的制造工序的自动化。
附图说明
图1是本发明的一实施方式的通气构件的分解立体图。
图2是图1所示的通气构件的剖视图。
图3是通气膜的剖视图。
图4是图1所示的通气构件的局部放大剖视图。
图5A是图1所示的通气构件的制造工序图。
图5B是接着图5A之后的制造工序图。
图5C是接着图5B之后的制造工序图。
图6是变形例的通气构件的剖视图。
图7是表示激光照射工序的图。
图8是变形例的罩盖的剖视图。
图9是以往的通气构件的侧视图。
具体实施方式
以下，参照附图，说明本发明的一实施方式。
如图1及图2所示，本实施方式的通气构件10具备通气膜2、支承体4、罩盖6及密封环8。通气结构50由具有通气用的开口部21的壳体20和安装于开口部21的通气构件10构成。壳体20具有需要通气的内部空间22。通过通气膜2，在内部空间22与外部空间24之间能够进行气体的往来。作为壳体20，可列举有例如汽车的ECU（ElectricControl Unit：电子控制单元）箱及灯箱。图1及图2仅表示壳体20的一部分。
通气膜2、支承体4及罩盖6分别具有俯视为圆形或正多边形的形状。轴线O通过通气膜2、支承体4及罩盖6的各中心。关于轴向，通气膜2所处的一侧为支承体4的上面侧，朝向壳体20的一侧为支承体4的下面侧。通气膜2的厚度方向与轴线O平行。与轴线O正交的方向定义为通气构件10的径向，换言之，定义为通气膜2的径向。
如图2所示，支承体4具有基台部11及腿部26。基台部11是对通气膜2进行支承的部分，具有大致圆盘的形状。在基台部11形成有作为内部空间22与外部空间24之间的通气路径的贯通孔3。腿部26是为了在壳体20上固定通气构件10而使用的部分，一体地形成于基台部11且从基台部11朝下延伸。腿部26沿着贯通孔3的周向分成多个部分（在本实施方式中为3个部分）。在通气结构50中，腿部26嵌合于开口部21。
通气膜2以在外部空间24侧将贯通孔3密闭的方式配置在基台部11上。通气膜2的结构及材料并未特别限定，作为通气膜2，可以使用具有容许气体的透过且阻止液体的透过的性质的膜。如图3所示，在本实施方式中，通气膜2具有膜主体2a和与膜主体2a叠合的加强件2b。通过设置加强件2b，而通气膜2的强度提高。当然，通气膜2也可以仅由膜主体2a构成。
也可以对膜主体2a实施防油处理及防水处理等防液处理。这些防液处理通过将表面张力小的物质涂敷于膜主体2a，在干燥后固化来进行。在防液处理中使用的防液剂可以形成比膜主体2a低的表面张力的皮膜，例如，优选包含具有全氟烷基的高分子的防液剂。防液剂通过浸渍、喷射等公知的方法而涂敷在膜主体2a上。
膜主体2a的典型例是由氟树脂或由聚烯烃形成的多孔质膜。从确保充分的防水性的观点出发，可以将具有0.01~10μm的平均孔径的树脂多孔质膜使用于膜主体2a。
作为适合于膜主体2a的氟树脂，可列举出聚四氟乙烯（PTFE）、聚三氟氯乙烯、四氟乙烯-六氟丙烯共聚物、四氟乙烯-乙烯共聚物。作为适合于膜主体2a的聚烯烃，可列举出乙烯、丙烯、4-甲基戊烯-1,1丁烯等的单体的聚合物或它们的共聚物。也可以使用纳米纤维膜多孔体，该纳米纤维膜多孔体利用了聚丙烯腈、尼龙、聚乳酸。其中，优选能够为小面积且确保高通气性并且在阻止异物向壳体的内部的侵入的能力方面也优异的PTFE。PTFE多孔质膜可以通过延伸法及抽出法等公知的成形方法来制造。
加强件2b可以是由聚酯、聚乙烯、芳族聚酰胺等的树脂制成的构件。加强件2b的形态只要能够维持通气膜2的通气性即可，并未特别限定，例如是织布、无纺布、网状物、网眼、海绵、泡沫或多孔体。膜主体2a也可以通过热层压、热熔敷、超声波熔敷或粘接剂而粘合在加强件2b上。
通气膜2的厚度考虑到强度及处理的容易性而处于例如1μm~5mm的范围。通气膜2的通气度处于以通过JIS（Japanese IndustrialStandards）P 8117规定的格利试验机法得到的格利值计为例如0.1~300秒/100cm3的范围。通气膜2的耐水压为例如1.0kPa以上。
密封环8设置在腿部26的根部。在本实施方式中，密封环8可以由具有橡胶弹性的材料、例如丁腈橡胶、乙烯-丙烯橡胶、硅橡胶、氟橡胶、丙烯酸橡胶、氢化丁腈橡胶等的弹性体形成。也可以取代弹性体，而密封环8由发泡体那样的其他的具有橡胶弹性的材料形成。
在壳体20的开口部21插入支承体4的腿部26时，利用夹在支承体4与壳体20之间的密封环8的弹性力，将支承体4沿着从壳体20脱落的方向压回。此时，在壳体20的内部空间22侧，腿部26与壳体20卡合，防止通气构件10从壳体20脱落的情况。需要说明的是，可以利用二色成形、嵌入成形等的方法，将与密封环8相当的部分一体地设置于支承体4。另外，也可以将密封环8粘接于支承体4。
罩盖6安装于支承体4以保护通气膜2。在通气膜2与罩盖6之间形成有空间AR1作为罩盖6的内部空间。空间AR1也作为内部空间22与外部空间24之间的通气路径而发挥作用。在本实施方式中，罩盖6利用激光熔敷而固定于支承体4。具体而言，如图4所示，在罩盖6与支承体4之间形成有将两者进行接合的第一激光熔敷部12。此外，通气膜2也通过激光熔敷而固定于支承体4。具体而言，在通气膜2与支承体4之间形成有将两者接合的第二激光熔敷部14。在通气膜2的径向上，可以将第二激光熔敷部14与第一激光熔敷部12连续地形成，也可以将第二激光熔敷部14从第一激光熔敷部12分离形成。根据前者的例子（即，图4所示的例子），第一激光熔敷部12及第二激光熔敷部14在俯视下整体具有单重环的形状。根据后者的例子，第一激光熔敷部12及第二激光熔敷部14在俯视下具有双重环的形状。
在本实施方式中，支承体4由相对容易吸收用于形成激光熔敷部12的激光的第一材料制成。罩盖6由比第一材料相对难以吸收激光且可使激光透过的第二材料制成。第一及第二材料包括例如相同或互不相同的种类的树脂作为主成分。支承体4及罩盖6由具有互不相同的性质的材料制成，因此能比较容易地形成高品质的激光熔敷部12。在使用同一树脂作为第一材料及第二材料的各主成分时，例如，能够由树脂中的添加剂的量及种类来调节激光的吸收容易度。当然，也可以使用树脂以外的材料，例如玻璃、金属。需要说明的是，“主成分”是指以质量比计含有最多的成分。
作为第一材料用的树脂，可以优选使用PBT（聚对苯二甲酸丁二醇酯）、PA（聚酰胺）、PET（聚对苯二甲酸乙二醇酯）等的热可塑性树脂、EPDM（三元乙丙橡胶）、硅橡胶等的热硬化性树脂。为了使激光容易吸收，可以在树脂中混合着色剂（染料及/或颜料）。作为着色剂，可以使用有机系着色剂、无机系着色剂或它们的组合。通过调节树脂中的着色剂的含有量，而能够控制激光照射时的发热量。例如，通过将染料系吸收色素和颜料系吸收色素组合使用，激光的照射时的发热量的控制容易化。此外，也可以将碳黑、钛白等的颜料、玻璃粒子、玻璃纤维等的加强用填料、防水材料等添加物混合到树脂中。
作为第二材料用的树脂，可以优选使用聚丙烯、聚乙烯、PBT、PA、PET等热可塑性树脂。为了使激光难以吸收，而优选使第二材料不含有上述的着色剂。但是，第二材料也可以含有着色剂。这种情况下，第二材料中的着色剂的质量含有率比第一材料中的着色剂的质量含有率小。
支承体4为不透明，典型地具有黑色。由此，促进激光的吸收而能够容易地形成激光熔敷部12及14。需要说明的是，“具有黑色”是指含有用于着色成黑色的着色剂。通常，按照JIS Z 8721明度（无彩色）中规定的黑色度，将1~4判断为“黑”，将5~8判断为“灰”，将9以上判断为“白”。在本实施方式中，支承体4只要为灰或黑（黑色度8以下）即可，从激光的吸收效率的观点出发，优选为黑（黑色度4以下）。
另一方面，罩盖6优选为透明，通过罩盖6能够视觉辨认激光熔敷部12及通气膜2。若罩盖6为透明，则能够在安装有罩盖6的状态下检查激光熔敷部12及通气膜2的外观。另外，能够在将罩盖6固定于支承体4的状态下实施通气膜2的耐水性的检査及异物的附着的有无的检査等各种检査。因此，根据本实施方式，不良品的发现容易，且还能够期待产品（通气构件10）的生产性及品质的提高。
但是，第二材料（罩盖6的材料）为透明的情况并非必须，第二材料也可能与第一材料同样地为不透明。这种情况下，第一材料具有相对小的黑色度，第二材料具有相对大的黑色度。
在利用第二激光熔敷部14将通气膜2与支承体4接合时，优选支承体4由容易吸收激光的第一材料制成，通气膜2由比第一材料难以吸收激光的材料制成。根据该结构，通过从通气膜2侧向通气膜2与支承体4的界面照射激光，能够比较容易地形成第二激光熔敷部14。具体而言，优选第一材料具有相对小的黑色度，通气膜2的结构材料具有相对大的黑色度。典型的情况是，通气膜2优选为白色的颜色，例如以黑色度计具有9以上。另外，为了使激光难以吸收，优选在通气膜2的结构材料中不含有上述的着色剂。例如，未着色的PTFE本质上具有白色的颜色，因此适合作为通气膜2的材料。
如图2及图4所示，罩盖6具有面向通气膜2的平坦的顶部31和从顶部31朝着支承体4向下延伸的圆筒状的檐部32。激光熔敷部12形成在檐部32的下表面与支承体4的上表面之间。根据这种结构，能够容易地确保在罩盖6与通气膜2之间具有充分宽的空间AR1。
详细而言，檐部32由在通气膜2的径向上与通气膜2的外周部分重合的内周部分32a和在通气膜2的径向上与通气膜2未重合的外周部分32b构成。在檐部32的外周部分32b与支承体4之间形成有第一激光熔敷部12。另外，在通气膜2的外周部分与支承体4之间形成有第二激光熔敷部14。檐部32的内周部分32a与通气膜2的外周部分重合，即，通气膜2的外周部分夹在支承体4与罩盖6之间，因此能够可靠地防止通气膜2从支承体4剥离。此外，在用于形成第二激光熔敷部14的激光照射工序中，可以利用罩盖6将通气膜2朝向支承体4按压。即，可以将罩盖6兼用作通气膜2的夹具。
如图2所示，罩盖6为了将罩盖6的内部空间（空间AR1）与外部空间24连通，还具有形成于顶部31的通气孔7。通气孔7在罩盖6的周向的整个区域容许形成第一激光熔敷部12。即，在本实施方式中，在俯视下，第一激光熔敷部12具有环的形状。根据这种结构，能够将罩盖6牢固地固定于支承体4。同样地，通过使第二激光熔敷部14具有环的形状，而能够将通气膜2牢固地固定于支承体4。另外，沿着顶部31的周向，多个通气孔7以等角度间隔形成。在本实施方式中，3个通气孔7以120°间隔形成。因此，即使水等液体从某通气孔7进入到罩盖6的内部空间，也能从另一通气孔7将液体向外部空间排出。
当然，在俯视下，激光熔敷部12及14也可以具有环以外的形状。例如，为了将罩盖6的内部空间（空间AR1）与外部空间24连通而可以将沿着水平方向开口的一个或多个通气孔设置在罩盖6的檐部32。在这样将一个或多个通气孔设置于檐部32时，第一激光熔敷部12在周向上可以在至少1个部位以上被切断。此外，在这样将一个或多个通气孔设置于檐部32时，可以从顶部31省去通气孔7。
另外，根据本实施方式，在俯视下，罩盖6的全部收纳在支承体4的内侧。即，可以从罩盖省去像以往的通气构件（参照图9）那样的用于将罩盖固定于支承体的卡合部。由于这种卡合部通常设置在罩盖的外周部，因此通过省略卡合部而能实现通气构件的简化及小型化。罩盖6具有非常简单的形状，因此例如可使用上下一对模具来成形。当然，本发明并未排除具有卡合部的以往的罩盖。可以取代不具有卡合部的罩盖6，如图6所示，使用具有能够与支承体4的外周部分卡合的卡合部6k的罩盖16。需要说明的是，在本实施方式中，支承体4的外径比罩盖6的外径大，但支承体4的外径也可以与罩盖6的外径一致。
接下来，说明通气构件的制造方法。首先，分别制成支承体4、通气膜2及罩盖6。支承体4及罩盖6可以通过注塑成形、压缩成形、切削成形等一般的成形方法来制成，典型的是通过注塑成形来制成。也可以对支承体4及罩盖6的表面实施用于促进液体的排除的防水处理。此外，也可以对支承体4及罩盖6实施易粘接处理、绝缘处理、半导体处理、导电处理等处理。
接下来，相对于支承体4而将通气膜2及罩盖6分别配置在规定的位置。首先，如图5A所示，将多个支承体4安装于夹具18。夹具18为了能够同时组装多个通气构件10而可以保持多个支承体4。支承体4由夹具18保持成其上表面成为水平平行的姿态。接下来，如图5B所示，以通气膜2的中心与支承体4的轴线O一致的方式在支承体4上配置通气膜2。为了防止通气膜2移动，也可以使用粘接剂将通气膜2临时固定于支承体4。接下来，如图5C所示，在支承体4上配置罩盖6。由此，能得到由支承体4、通气膜2及罩盖6构成的组装体10’。
接下来，向由支承体4、通气膜2及罩盖6构成的组装体10’照射激光，以便于利用透过了罩盖6的激光至少使支承体4的一部分熔化，从而形成将罩盖6与支承体4接合的激光熔敷部12。需要说明的是，在支承体4由先前说明的第二材料构成且罩盖6由先前说明的第一材料构成时，可以利用透过了支承体4的激光至少使罩盖6的一部分熔化，由此来形成激光熔敷部12。
具体而言，如图7所示，在罩盖6上覆盖使激光透过的夹具40（典型的是透明的玻璃板），以在支承体4与罩盖6之间夹持通气膜2的方式对夹具40施加压力。维持该状态，并如上述那样，向组装体10’照射激光。如图8所示，当在罩盖6设置锪孔6g时，通气膜2的厚度难以成为如下情况的原因，即使将罩盖6与支承体4接合的第一激光熔敷部12的形成困难的原因。为了能够使通气膜2的外周部分嵌入锪孔6g，而将锪孔6g设置在通气膜2的檐部32的下表面。锪孔6g具有例如通气膜2的厚度的1/3~1/2左右的深度。当然，在通气膜2薄时，不需要这种锪孔6g。
在本实施方式中，支承体4由容易吸收激光的第一材料制成，罩盖6由比第一材料难以吸收激光的第二材料制成。因此，在激光照射工序中，透过罩盖6而对罩盖6的檐部32与支承体4的界面照射激光。支承体4具有腿部26，因此容易利用夹具夹持。因此，在将支承体4保持为不动的状态下透过罩盖6对界面照射激光的方法从通气构件10的设计的观点出发是合理的。
在本实施方式中，在形成了组装体10’的状态下，罩盖6的檐部32包括：在通气膜2的径向上应与通气膜2的外周部分相接的内周部分32a；在通气膜2的径向上应与支承体4相接的外周部分32b。这种情况下，激光照射工序可由下述（i）所示的第一照射工序和下述（ii）所示的第二照射工序构成。第一照射工序（i）是为了在檐部32的外周部分32b与支承体4之间形成第一激光熔敷部12，而透过罩盖6对檐部32的外周部分32b与支承体4的界面照射激光的工序。第二照射工序（ii）是为了在通气膜2的外周部分与支承体4之间形成将通气膜2与支承体4接合的第二激光熔敷部14而透过罩盖6对通气膜2的外周部分与支承体4的界面照射激光的工序。如此，能够有效地形成第一激光熔敷部12及第二激光熔敷部14，因此通气构件10的生产性提高。
在第一照射工序中，由激光的照射而使支承体4的表面部熔融及固化，由此能够将罩盖6与支承体4接合。在第二照射工序中，支承体4的表面部熔融，并且熔化的树脂进入到构成通气膜2的多孔质膜（膜主体2a）的微细孔。进入到微细孔而固化了的树脂产生固着效果，由此，将通气膜2牢固地固定于支承体4。
第一照射工序中的激光熔敷的条件可以与第二激光照射工序中的激光熔敷的条件相同，也可以不同。各照射工序中的激光熔敷的条件应适当调节，以免对各部件造成过度的损害。例如，将激光输出在20~300W（或20~50W）的范围内调节，将激光波长在800~1100nm（或800~950nm）的范围内调节。激光的种类并未特别限定，可以使用CO2激光、受激准分子激光等气体激光、半导体激光、YAG激光（yttriumaluminum garnet laser：钇铝石榴石激光）等固体激光。
根据以往的热熔敷，熔敷的精度会受到用于向界面赋予热量的熔敷珩磨头与对工件（通气膜及支承体）进行保持的熔敷台的平行度的较大影响。然而，根据激光熔敷，由加工装置带来的误差难以反映到产品（通气构件）的完成品中。因此，通过采用激光熔敷而能够期待成品率的提高。
需要说明的是，在将罩盖6配置在支承体4上之前的时刻，也可以将通气膜2熔敷于支承体4。即，在图5B所示的时刻，使用激光熔敷、热熔敷及超声波熔敷等熔敷方法，将通气膜2熔敷于支承体4。这种情况下，先于激光熔敷部12而形成将通气膜2与支承体4接合的熔敷部（激光熔敷部、热熔敷部或超声波熔敷部）。
通过以上说明的方法，能够制造出参照图1~图4说明的通气构件10。根据本实施方式的通气构件10，由于罩盖6透明，因此能容易地进行外观检査。因此，容易发现不良品，在品质管理的方面比以往的通气构件有利。
（变形例）
利用具有橡胶弹性的材料来构成支承体，由此能够提供省略了应与壳体20的开口部21卡合的腿部的通气构件。这种通气构件利用支承体的弹性而安装在壳体20的开口部21。此外，也可以考虑“支承体”是构成壳体20的一部分的部件、例如构成壳体20的盖部或底部的部件。
根据图5A~图5C所示的例子，能够连续地制造多个通气构件10。这里，作为应熔敷于支承体4的通气膜2，也可以考虑使用由与通气膜2相同材料构成的1张片的形态。这种情况下，将该1张片配置在多个支承体4上，并对各支承体4照射激光以形成第二激光熔敷部14。然后，利用激光加工将1张片切断，以便于从1张片得到规定的形状（典型的是圆形）的通气膜2。根据这种方法，能够排除对切断成规定形状的通气膜2进行处理的必要性。
同样地，作为应熔敷于支承体4的罩盖6，也可以考虑使用由与罩盖6相同材料构成的1张板材的形态。这种情况下，将该1张板材配置在多个支承体4上，并对各支承体4照射激光以形成第一激光熔敷部12。然后，利用激光加工将1张板材切断，以便于从1张板材得到规定的形状（典型的是圆形）的罩盖6。为了从1张板材得到多个罩盖6而在板材上预先制成通气孔7和与空间AR1对应的凹部。根据这种方法，能够排除对切断成规定形状的罩盖6进行处理的必要性。即使板材透明，通过使用CO2激光（例如，10.6μm的远红外区域波长，振荡效率15~20%的激光）、YAG激光（例如，1.06μm的红外区域波长的激光）也能够将所述板材切断。
【工业实用性】
本发明的通气构件可以使用于灯、电动机、传感器、开关、ECU、齿轮箱等的汽车部件的壳体。另外，不仅是汽车部件，而且在移动体通信设备、相机、电剃刀、电动牙刷等的电气产品中也可以使用本发明的通气构件。

Claims (11)

1.一种通气构件，能够安装于具有通气用的开口部的壳体上，其具备：
支承体，其具有所述壳体的内部空间与外部空间之间的通气路径；
通气膜，其配置在所述支承体上，且在所述外部空间侧将所述通气路径密闭；
罩盖，其安装于所述支承体以保护所述通气膜；及
激光熔敷部，其将所述罩盖与所述支承体接合。
2.根据权利要求1所述的通气构件，其中，
所述支承体由容易吸收用于形成所述激光熔敷部的激光的第一材料制成，
所述罩盖由比所述第一材料难以吸收所述激光且能使所述激光透过的第二材料制成，
所述第一及第二材料包括相同或互不相同的种类的树脂作为主成分。
3.根据权利要求1所述的通气构件，其中，
所述罩盖透明，能够透过所述罩盖而视觉辨认所述激光熔敷部及所述通气膜。
4.根据权利要求1所述的通气构件，其中，
还具备将所述通气膜与所述支承体接合的第二激光熔敷部。
5.根据权利要求1所述的通气构件，其中，
所述罩盖具有面向所述通气膜的顶部及从所述顶部朝着所述支承体而向下延伸的檐部，
在所述檐部的下表面与所述支承体的上表面之间形成有所述激光熔敷部。
6.根据权利要求4所述的通气构件，其中，
所述罩盖具有面向所述通气膜的顶部及从所述顶部朝着所述支承体而向下延伸的檐部，
所述檐部包括在所述通气膜的径向上与所述通气膜的外周部分重合的内周部分、及在所述通气膜的径向上未与所述通气膜重合的外周部分，
在所述檐部的所述外周部分与所述支承体之间形成作为第一激光熔敷部的所述激光熔敷部，
在所述通气膜的所述外周部分与所述支承体之间形成有所述第二激光熔敷部。
7.根据权利要求5所述的通气构件，其中，
所述罩盖还具有以将该罩盖的内部空间与所述外部空间连通的方式形成于所述顶部的通气孔，
在俯视下，所述激光熔敷部具有环的形状。
8.根据权利要求1所述的通气构件，其中，
在俯视下，所述罩盖的全部收纳在所述支承体的内侧。
9.一种通气构件的制造方法，制造能够安装于具有通气用的开口部的壳体上的通气构件，所述通气构件的制造方法包括如下工序：
准备支承体、通气膜、罩盖的工序，该支承体具有所述壳体的内部空间与外部空间之间的通气路径，该通气膜在所述外部空间侧将所述通气路径密闭，该罩盖应安装于所述支承体上以保护所述通气膜；
相对于所述支承体而将所述通气膜及所述罩盖分别配置在规定的位置上的工序；及
向由所述支承体、所述通气膜及所述罩盖构成的组装体照射激光的工序，从而透过了所述罩盖的所述激光使所述支承体的一部分熔化或透过了所述支承体的所述激光使所述罩盖的一部分熔化，由此形成将所述罩盖与所述支承体接合的激光熔敷部。
10.根据权利要求9所述的通气构件的制造方法，其中，
所述支承体由容易吸收用于形成所述激光熔敷部的激光的第一材料制成，
所述罩盖由比所述第一材料难以吸收所述激光且能使所述激光透过的第二材料制成，
所述罩盖具有面向所述通气膜的顶部及从所述顶部朝着所述支承体而向下延伸的檐部，
在所述激光照射工序中，透过所述罩盖对所述檐部与所述支承体的界面照射所述激光。
11.根据权利要求10所述的通气构件的制造方法，其中，
所述檐部包括在所述通气膜的径向上应与所述通气膜的外周部分相接的内周部分、及在所述通气膜的径向上应与所述支承体相接的外周部分，
所述激光照射工序包括如下工序：
（i）透过所述罩盖对所述檐部的所述外周部分与所述支承体之间的界面照射所述激光，以在所述檐部的所述外周部分与所述支承体之间形成所述激光熔敷部；
（ii）透过所述罩盖对所述通气膜的所述外周部分与所述支承体之间的界面照射所述激光，以在所述通气膜的所述外周部分与所述支承体之间形成将所述通气膜与所述支承体接合的第二激光熔敷部。
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US10420238B2 (en) 2014-06-02 2019-09-17 Nitto Denko Corporation Housing kit and ventilation housing
CN106416444B (zh) * 2014-06-02 2019-11-26 日东电工株式会社 框体成套工具及通气框体
CN109642710A (zh) * 2016-08-30 2019-04-16 日东电工株式会社 通气构件以及检查方法
CN109950742A (zh) * 2017-12-20 2019-06-28 住友电装株式会社 防水连接器
CN109798487A (zh) * 2019-03-12 2019-05-24 芜湖安瑞光电有限公司 一种便于更换干燥剂的车灯

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US20130012117A1 (en) 2013-01-10
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WO2011114640A1 (ja) 2011-09-22
EP2549175A1 (en) 2013-01-23
JP5519352B2 (ja) 2014-06-11

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