CN104080305A - 防水通气结构、防水通气构件及防水通气膜 - Google Patents

防水通气结构、防水通气构件及防水通气膜 Download PDF

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CN104080305A
CN104080305A CN201410113802.3A CN201410113802A CN104080305A CN 104080305 A CN104080305 A CN 104080305A CN 201410113802 A CN201410113802 A CN 201410113802A CN 104080305 A CN104080305 A CN 104080305A
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古内浩二
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Nitto Denko Corp
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Abstract

本发明提供一种防水通气结构、防水通气构件及防水通气膜，所述防水通气结构具备：壳体，具备内部空间和将内部空间与外部空间连通的开口部；及防水通气膜，以将开口部堵塞的方式配置，防水通气膜是包括含有填料的第一延伸聚四氟乙烯（PTFE）多孔膜和不含有填料的第二延伸PTFE多孔膜（2）的层叠体，以第二延伸PTFE多孔膜（2）相比第一延伸PTFE多孔膜（1）位于内部空间（22）侧的方式配置防水通气膜（11）。根据本发明，提供一种填料难以向壳体内部脱落的防水通气结构。

Description

防水通气结构、防水通气构件及防水通气膜
技术领域
本发明涉及一种使用了延伸聚四氟乙烯（PTFE）多孔膜的防水通气结构，而且涉及一种适合于实现该防水通气结构的防水通气构件及防水通气膜。
背景技术
在灯、压力传感器、ECU（Electronic Control Unit）等车辆用电气部件、便携式电话、智能手机、笔记本电脑、数码相机等便携用电子设备、及电动牙刷、电动剃须刀等小型家电产品的壳体上，为了确保壳体内外的通气而大多设有开口部。开口部消除伴随着壳体内外的温度差而产生的压力差，而且，在将麦克风、扬声器等电气音响转换部件配置于壳体的内部时，能确保壳体的内部与外部之间的通音性。为了防止水向壳体的内部的侵入，在开口部配置防水通气膜的情况逐渐增加。防水通气膜典型的是延伸而多孔化的PTFE膜（延伸PTFE多孔膜）。
为了便于向开口部的安装，也已知有防水通气膜与固定用构件预先被一体化的防水通气构件。作为固定用构件，使用例如在防水通气膜的周缘部粘贴的双面粘接带。固定用构件的另一例是在内部具有通气路的树脂构件。在该树脂构件上以将内部的通气路堵塞的方式预先固定有防水通气膜，仅通过将防水通气构件向开口部压入，防水通气膜就能以将开口部堵塞的方式配置。防水通气构件的例子在专利文献1～4中公开。
延伸PTFE多孔膜原本为白色。然而，在配置于开口部的膜为了能够让使用者视觉辨认的用途中，有时从美观上其他的理由出发而要求着色后的延伸PTFE多孔膜。而且，延伸PTFE多孔膜原本为绝缘性。然而，例如为了防止电磁波向壳体内的侵入而有时希望向延伸PTFE多孔膜赋予导电性。因此，在延伸PTFE多孔膜中，有时混合有与应赋予的特性对应的填料。代表性的填料是为了着色及/或赋予导电性而混合的碳黑。着色后的延伸PTFE多孔膜例如在专利文献4的段落0029中公开。
【在先技术文献】
【专利文献】
【专利文献1】日本特开2001-143524号公报
【专利文献2】日本特开2004-47425号公报
【专利文献3】日本特开2008-237949号公报
【专利文献4】日本特表2003-503991号公报
延伸PTFE多孔膜具有由原纤维及结节构成的特征性的微多孔结构，该微多孔结构比无纺布等一般的通气性材料的内部结构更微细。因此，延伸PTFE多孔膜在填料的保持力方面优越。然而，本发明者发现，由于伴随着车辆的行驶而向车辆用电气部件长期施加的振动、或者在便携用电子设备或小型家电产品的落下时施加的冲击，存在填料从混合有填料的延伸PTFE多孔膜脱落的可能性。脱落的填料可能会给配置在壳体内的电子部件造成影响。
发明内容
因此，本发明目的在于提供一种具备混合有填料的延伸PTFE多孔膜且填料难以向壳体内部脱落的防水通气结构。而且，本发明的另一目的在于提供一种适合于实现该防水通气结构的防水通气构件及防水通气膜。
【解决方案】
本发明提供一种防水通气结构，具备：
壳体，具备内部空间和将所述内部空间与外部空间连通的开口部；及
防水通气膜，以将所述开口部堵塞的方式配置，
所述防水通气膜是包括含有填料的第一延伸PTFE多孔膜和不含有填料的第二延伸PTFE多孔膜的层叠体，
以所述第二延伸PTFE多孔膜相比所述第一延伸PTFE多孔膜位于所述内部空间侧的方式配置所述防水通气膜。
另外，本发明提供一种防水通气结构，具备：
防水通气膜；及
固定用构件，与所述防水通气膜的周缘部接合，
所述防水通气膜是包括含有填料的第一延伸PTFE多孔膜和不含有填料的第二延伸PTFE多孔膜的层叠体。
此外，本发明提供一种防水通气膜，是包括含有填料的第一延伸PTFE多孔膜和不含有填料的第二延伸PTFE多孔膜的层叠体。
【发明效果】
根据本发明的防水通气结构，即使从含有填料的第一延伸PTFE多孔膜发生填料脱落，不含有填料的第二延伸多孔膜也能承接脱落的填料。因此，成为填料难以向壳体内部落下的防水通气结构。而且，本发明的防水通气构件及防水通气膜可以作为适合于本发明的防水通气结构的制造的部件使用。
附图说明
图1是表示本发明的防水通气结构的一例的剖视图。
图2是图1所示的防水通气结构所使用的防水通气构件的立体图。
图3是表示本发明的防水通气结构的另一例的局部剖切剖视图。
图4是图3所示的防水通气结构所使用的防水通气构件的分解立体图。
具体实施方式
以下，参照附图，说明本发明的实施方式。
图1所示的防水通气结构100具备：具有开口部21的壳体20；以将开口部21堵塞的方式配置的防水通气膜11。壳体20的内部空间22与外部空间经由通过防水通气膜11堵塞的开口部21而连通，通过开口部21的气体通过防水通气膜11而向壳体20的内部空间22侵入，或者向外部空间排出。
防水通气膜11是层叠体，包括：含有填料的第一延伸PTFE多孔膜1；不含有填料的第二延伸PTFE多孔膜2。在图示的方式中，两延伸多孔膜1、2具有相同的面形状，但是只要在从垂直于膜面的方向观察时将第一延伸PTFE多孔膜1覆盖，第二延伸PTFE多孔膜2就也可以比第一延伸PTFE多孔膜1大。而且，也可以将延伸多孔膜1、2以外的膜向防水通气膜11附加。作为可以附加的膜，可列举追加的延伸PTFE多孔膜（第三延伸PTFE多孔膜）。第三延伸PTFE多孔膜例如在为了进一步提高耐水性的目的下被追加。需要说明的是，防水通气膜11的耐水性通过基于JIS L1092高水压法的测定值来表示，优选为30kPa以上，更优选为50kPa以上。
可以向防水通气膜11附加的膜的另一例是无纺布、织布、网等通气性支承材料。通气性支承材料对防水通气膜进行加强而提高其机械强度，并提高其处理性。但是，根据在配置防水通气膜11的壳体的内部配置的电子部件的种类的不同，希望从防水通气膜11将通气性支承材料去除。例如电子部件为麦克风、扬声器、蜂鸣器等电气音响转换部件的情况下，防水通气膜11的每单位面积质量优选不会过大。这是因为，防水通气膜11的通音特性不仅受到膜的通气特性的影响，而且也受到膜的振动特性的影响。因此，在壳体的内部空间配置电气音响转换部件而应重视防水通气膜11的通音性的情况下，防水通气膜11优选仅由将第一延伸PTFE多孔膜1与第二延伸PTFE多孔膜2直接层叠而成的双层膜构成。
在防水通气膜11的周缘部接合有双面粘接带（以下，表述为双面胶带）31、32作为固定用构件30。双面胶带31介于第一延伸PTFE多孔膜1与壳体20之间而将防水通气膜11固定于壳体20，双面胶带32介于第二延伸PTFE多孔膜2与电子部件40之间而将防水通气膜11固定于电子部件40。作为适合于与防水通气膜11一起一体化于壳体20进行使用的电子部件40，可列举上述例示的电气音响转换部件。但是，通过第二延伸PTFE多孔膜2而与防水通气膜11接合的对方的构件并不局限于电子部件，可以是介于电气音响转换部件与防水通气膜之间的衬垫、间隔件等辅助构件、从壳体的内表面向内部延伸的支承构件等。需要说明的是，在图示的方式中，双面胶带31、32配置在防水通气膜11的两面上，但是在只要将防水通气膜11仅固定于壳体20即可的情况下，可以仅配置一方的双面胶带31（32）。这种情况下，与图示的方式不同，可以将防水通气膜11固定在壳体20的外周面。在此方式中，与第二延伸PTFE多孔膜2的周缘部接合的双面胶带32被粘贴于壳体20的外周面。
如图2所示，在防水通气构件50中，双面胶带31、32配置在防水通气膜11的周缘区域6整个区域。换言之，双面胶带31、32在防水通气膜11上形成闭合的框，通过该闭合的框将防水通气膜11的通气区域5包围。在图示的方式中，双面胶带31、32具有相同的面形状，在从垂直于防水通气膜11的膜面的方向观察时以相互重叠的方式配置在膜的周缘区域6。双面胶带31、32由基材和形成在基材的两面上的粘接层构成，但是作为固定用构件30，也可以使用单层的粘接剂层。而且，在图示的方式中，使用了环状的双面胶带31、32，但是双面胶带或单层的粘接剂层的形状并不局限于此，也可以是例如矩形的框状。
为了实现防水通气结构100，而使用具备防水通气膜11和固定用构件30的防水通气构件50。图1及图2所示的固定用构件30是双面胶带31、32，但是如上述那样，固定用构件30的另一例是在内部具有通气路的树脂构件。防水通气结构110如图3及图4所示，其使用了将树脂构件设为固定用构件30的防水通气构件的一例。防水通气构件51具备支承体60作为固定用构件30，该支承体60在内部具有通气路68，支承体60在将通气路68的一端包围的支承部61上对防水通气膜12在膜的周缘区域整个区域进行支承。支承体60具备和支承部61一起从壳体20的开口部21向其内部插入的插入部64，插入部64被从其插入侧前端沿着插入方向延伸的狭缝67分割成多个支腿部65。而且，在多个支腿部65的至少一个的外周面上形成有卡止部66。形成有卡止部66的支腿部65被向壳体20的内部压入而在通过开口部21时向内周侧发生弹性变形，在通过了开口部21之后向外周侧复原。在此状态下，卡止部66卡合于与开口部21相邻的壳体20的内表面，防止支承体60从开口部21的脱落。
防水通气构件51还具备有底的罩70，罩70具备底部71和从底部71向防水通气膜12侧延伸的多个爪部72。爪部72卡合于支承体60的侧部，使罩70与支承体60一体化。在此状态下，多个爪部72之间的空隙73构成能够使壳体20的内部空间通气的通气路的一部分。而且，在此状态下，底部71在从垂直于防水通气膜12的膜面的方向观察时成为将防水通气膜12的整个区域覆盖的保护部。需要说明的是，在防水通气构件51与壳体20的外周面之间介有O形环80，通过其复原力将爪部72可靠地卡止于壳体20壁面，并防止水等从防水通气构件51与壳体20外面的间隙向开口部21侵入的情况。若使用将防水通气膜12预先接合于固定用构件30（60）的防水通气构件51，则能够与防水通气构件50同样地将防水通气膜12简便且可靠地固定于壳体20。
防水通气膜12是将含有填料的第一延伸PTFE多孔膜1、不含有填料的第二延伸PTFE多孔膜2、通气性支承材料3依次层叠而成的层叠体。通气性支承材料3为了提高强度及处理性而被附加。作为通气性支承材料3，优选不含有填料的无纺布、织布、网等。
通气性支承材料3的空隙率比延伸PTFE多孔膜的空隙率高的情况是通例。因此，从将填料脱落的可能性抑制得更低的观点出发，优选在延伸PTFE多孔膜1、2之间不介有通气性支承材料3，而将第一延伸PTFE多孔膜1与第二延伸PTFE多孔膜2直接接合。这是为了排除从第一延伸PTFE多孔膜1脱离的填料从通气性支承材料3侧面向膜的外部脱落的可能性。因此，无论电子部件40是否为音响部件，防水通气膜11、12都优选包括将第一延伸PTFE多孔膜1与第二延伸PTFE多孔膜2直接层叠而成的双层膜。
延伸PTFE多孔膜1、2的膜厚没有特别限定，例示的话如以下所述。含有填料的第一延伸PTFE多孔膜1的膜厚优选为1～500μm，更优选为5～300μm。不含有填料的第二延伸PTFE多孔膜2的膜厚优选为1～500μm，更优选为5～300μm。将第一延伸PTFE多孔膜1与第二延伸PTFE多孔膜2直接接合而成的层叠体的膜厚优选为2～1000μm，更优选为10～600μm。
填料只要根据用途而适当选择即可，其种类没有特别限定，例如为着色用填料及/或导电性填料。在以着色为目的时，现实的情况多希望使用碳黑、石墨等碳系黑色颜料，但并不局限于此，可以使用与壳体的颜色等对应的各种着色料。为了赋予导电性，碳黑、石墨等碳系导电性填料的使用比较有效。导电性填料的另一例是金属粉末。
在填料向延伸PTFE多孔膜的混合中，能够通过向延伸的PTFE片预先混合填料而实施。具体而言，在将PTFE细粉与液状润滑剂混合而制造PTFE成形体时，添加填料即可。然后按照本领域技术人员周知的工序，能够得到混合有填料的延伸PTFE多孔膜。延伸PTFE多孔膜正如周知那样，通常经由基于所谓的双轴延伸的膜的多孔化而制造。
将混合有填料的第一延伸PTFE多孔膜与未混合填料的第二延伸PTFE多孔膜直接接合所得到的双层膜优选通过使上述的延伸PTFE多孔膜、仅向1方向延伸的单轴延伸PTFE膜、或延伸前的PTFE片重叠并烧制，而一体化地制造。PTFE的烧制通过加热至PTFE的熔点（327℃）以上的温度来进行。一体化用的烧制也可以一边对膜进行延伸一边实施。
以下，通过实施例更详细地说明本发明，但本发明不受以下的实施例的限制。
（实施例）
制作了向100重量部的PTFE细粉（Daikin工业制F104）添加20重量部的液状润滑剂（正癸烷）及2重量部的碳黑（东海碳制#4500）的糊剂状的混和物，通过糊剂挤压而成形为圆棒状，接着轧制成厚度0.2mm而得到了PTFE片。接下来，在150℃的干燥炉内从PTFE片将液状润滑剂去除。然后，使PTFE片沿其长度方向以280℃延伸成5倍而得到了单轴延伸含填料PTFE膜。而且，除了未混合碳黑之外与上述同样地得到了单轴延伸不含填料PTFE膜。
将单轴延伸含填料PTFE膜与单轴延伸不含填料PTFE膜层叠后使其通过辊之间而进行压接，沿其宽度方向以130℃延伸成10倍，接着使其通过360℃的炉而进行了烧制。这样，得到了将含有填料的延伸PTFE多孔膜与不含有填料的延伸PTFE多孔膜直接层叠而成的PTFE多孔膜层叠体。PTFE多孔膜层叠体的厚度为40μm。而且，按照JISL1092高水压法，层叠的PTFE多孔膜层叠体的耐水压为200kPa。
将上述PTFE多孔膜层叠体冲裁成直径20mm的圆形而得到了防水通气膜。接着，在距不含有填料的延伸PTFE多孔膜的露出面的外周为5mm的宽度的周缘部粘贴预先冲裁成环状的双面胶带（日东电工制No.500）的一侧的面。对于如此得到的防水通气构件，在设于长方体的容器上的直径10mm的圆形的孔的周边部从其外侧粘贴双面胶带的另一侧的面，从而利用防水通气膜将容器的孔堵塞。使该容器从高度1m的高度落下之后，对容器内部进行了确认时，未确认到碳黑向容器内部的脱落。
（比较例）
除了节省了将与实施例同样得到的单轴延伸含填料PTFE膜与单轴延伸不含填料PTFE膜进行层叠及压接的工序之外，与实施例同样地得到了含有填料的延伸PTFE多孔膜。该单层的延伸PTFE多孔膜的厚度为20μm。而且，按照JIS L1092高水压法，层叠的延伸PTFE多孔膜的耐水压为10kPa。除了取代PTFE多孔膜层叠体而使用由上述得到的单层的延伸PTFE多孔膜之外，与实施例同样地实施了碳黑的脱落试验时，确认到了碳黑向容器内部的脱落。

Claims (9)

1.一种防水通气结构，具备：
壳体，具备内部空间和将所述内部空间与外部空间连通的开口部；及
防水通气膜，将所述开口部堵塞，
所述防水通气膜是包括含有填料的第一延伸聚四氟乙烯多孔膜和不含有填料的第二延伸聚四氟乙烯多孔膜的层叠体，
以所述第二延伸聚四氟乙烯多孔膜相比所述第一延伸聚四氟乙烯多孔膜位于所述内部空间侧的方式配置所述防水通气膜。
2.根据权利要求1所述的防水通气结构，其中，
所述层叠体包括将所述第一延伸聚四氟乙烯多孔膜与所述第二延伸聚四氟乙烯多孔膜直接层叠而成的双层膜。
3.根据权利要求2所述的防水通气结构，其中，
所述层叠体仅由所述双层膜构成。
4.一种防水通气结构，具备：
防水通气膜；及
固定用构件，与所述防水通气膜的周缘部接合，
所述防水通气膜是包括含有填料的第一延伸聚四氟乙烯多孔膜和不含有填料的第二延伸聚四氟乙烯多孔膜的层叠体。
5.根据权利要求4所述的防水通气结构，其中，
所述层叠体包括将所述第一延伸聚四氟乙烯多孔膜与所述第二延伸聚四氟乙烯多孔膜直接层叠而成的双层膜。
6.根据权利要求5所述的防水通气结构，其中，
所述层叠体仅由所述双层膜构成。
7.一种防水通气膜，是包括含有填料的第一延伸聚四氟乙烯多孔膜和不含有填料的第二延伸聚四氟乙烯多孔膜的层叠体。
8.根据权利要求7所述的防水通气膜，其中，
所述层叠体包括将所述第一延伸聚四氟乙烯多孔膜与所述第二延伸聚四氟乙烯多孔膜直接层叠而成的双层膜。
9.根据权利要求8所述的防水通气膜，其中，
所述层叠体仅由所述双层膜构成。
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