CN105555506A - 将金属构件和树脂构件彼此接合的方法、冷却器的制造方法及冷却器 - Google Patents

将金属构件和树脂构件彼此接合的方法、冷却器的制造方法及冷却器 Download PDF

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Publication number
CN105555506A
CN105555506A CN201480051349.6A CN201480051349A CN105555506A CN 105555506 A CN105555506 A CN 105555506A CN 201480051349 A CN201480051349 A CN 201480051349A CN 105555506 A CN105555506 A CN 105555506A
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China
Prior art keywords
temperature
frame body
load
functional group
junction surface
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Granted
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CN201480051349.6A
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English (en)
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CN105555506B (zh
Inventor
中村秀生
柴田义范
杉山彻
山本右
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Toyota Motor Corp
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Toyota Motor 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
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/32—Measures for keeping the burr form under control; Avoiding burr formation; Shaping the burr
    • B29C66/324—Avoiding burr formation
    • 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
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • 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
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/24—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools characterised by the means for heating the tool
    • B29C65/30—Electrical means
    • 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
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/44—Joining a heated non plastics element to a plastics element
    • 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
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • 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
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
    • 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
    • B29C65/82—Testing the joint
    • B29C65/8207—Testing the joint by mechanical methods
    • B29C65/8246—Pressure tests, e.g. hydrostatic pressure tests
    • 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
    • B29C66/01—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
    • B29C66/028—Non-mechanical surface pre-treatments, i.e. by flame treatment, electric discharge treatment, plasma treatment, wave energy or particle radiation
    • 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
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/03—After-treatments in the joint area
    • B29C66/034—Thermal after-treatments
    • B29C66/0342—Cooling, e.g. transporting through welding and cooling zone
    • 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
    • B29C66/01—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
    • 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
    • B29C66/01—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
    • B29C66/114—Single butt joints
    • 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
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/32—Measures for keeping the burr form under control; Avoiding burr formation; Shaping the burr
    • 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
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/342—Preventing air-inclusions
    • 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
    • B29C66/50—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
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/534—Joining single elements to open ends of tubular or hollow articles or to the ends of bars
    • B29C66/5346—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat
    • B29C66/53461—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat joining substantially flat covers and/or substantially flat bottoms to open ends of container bodies
    • 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
    • B29C66/50—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
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • 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
    • B29C66/542—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 joining hollow covers or hollow bottoms to open ends of container bodies
    • 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
    • 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
    • B29C66/73—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
    • 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
    • B29C66/74—Joining plastics material to non-plastics material
    • B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
    • 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
    • B29C66/818—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 cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps
    • B29C66/8181—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 cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the cooling constructional aspects
    • B29C66/81811—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 cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the cooling constructional aspects of the welding jaws
    • 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
    • B29C66/818—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 cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps
    • B29C66/8187—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 cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the electrical insulating constructional aspects
    • B29C66/81871—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 cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the electrical insulating constructional aspects of the welding jaws
    • 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
    • B29C66/82—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps
    • B29C66/824—Actuating mechanisms
    • B29C66/8246—Servomechanisms, e.g. servomotors
    • 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
    • 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
    • B29C66/90—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
    • B29C66/912—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux
    • B29C66/9121—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature
    • B29C66/91211—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature with special temperature measurement means or methods
    • B29C66/91212—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature with special temperature measurement means or methods involving measurement means being part of the welding jaws, e.g. integrated in the welding jaws
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/90—Measuring or controlling the joining process
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    • B29C66/912—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux
    • B29C66/9121—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature
    • B29C66/91231—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature of the joining tool
    • 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
    • B29C66/90—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
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91411—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the parts to be joined, e.g. the joining process taking the temperature of the parts to be joined into account
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
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  • General Chemical & Material Sciences (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Cooling Or The Like Of Semiconductors Or Solid State Devices (AREA)
  • Details Of Heat-Exchange And Heat-Transfer (AREA)
  • Laminated Bodies (AREA)

Abstract

向金属构件(1)的表面上施加极性官能团。树脂构件(2)含有粘合性官能团。所述粘合性官能团和所述极性官能团彼此吸引。一种将金属构件(1)和树脂构件(2)彼此接合的方法包括：在使用第一载荷使金属构件(1)和树脂构件(2)彼此压靠的同时，加热金属构件(1)和树脂构件(2)之间的接合部；在使用小于第一载荷的第二载荷使金属构件(1)和树脂构件(2)彼此压靠的同时，将接合部的温度保持高于构成树脂构件(2)的树脂的熔融温度；和在使用大于第二载荷的第三载荷使金属构件和树脂构件彼此压靠的同时，冷却接合部至低于该熔融温度的温度。

Description

将金属构件和树脂构件彼此接合的方法、冷却器的制造方法及冷却器
技术领域
本发明涉及将金属构件和树脂构件彼此接合的方法、冷却器的制造方法和冷却器。
背景技术
近年来已开发出各种类型的工业产品，其中将具有优异的导热性、导电性、延展性等的金属构件与轻质且价廉的树脂构件彼此接合。不用说，在此类工业产品中，金属构件和树脂构件之间的由不同材料制成的接合部的可靠性成为一个问题。
日本专利申请公开号2010-173274(JP2010-173274A)中公开了一种接合方法，其中，为了使金属构件与树脂构件刚性地彼此粘附，向金属构件的表面上施加极性官能团，并且使含有粘合性官能团的粘合性改性剂与构成树脂构件的树脂组合，所述粘合性官能团与上面提到的极性官能团相互作用。
本发明人已发现以下问题。在JP2010-173274A中公开的接合方法中，为了促进施加到金属构件的表面上的极性官能团与树脂中所含的粘合性官能团之间的反应，有必要在将金属构件和树脂构件加热至树脂熔融温度或更高后使金属构件与树脂构件彼此接触给定的时间段。因此，当在接合的同时保持金属构件和树脂构件彼此压制时，存在从接合部突出的树脂(或溢料)增多的问题。同时，如果为了抑制接合部中溢料的产生而不使金属构件和树脂构件彼此压制，则存在接合部中树脂构件内残留因树脂的熔化而产生的气泡的问题，从而导致强度下降。
发明内容
本发明提供了一种将金属构件和树脂构件彼此接合的方法，通过所述方法，接合部中溢料的产生得以抑制并且因气泡所致的强度下降得以抑制。
根据本发明的一个方面的将金属构件和树脂构件彼此接合的方法包括以下构成。向金属构件的表面上施加极性官能团。树脂构件含有粘合性官能团。粘合性官能团与极性官能团彼此吸引。所述方法包括：在使用第一载荷使金属构件和树脂构件彼此压靠的同时，加热金属构件与树脂构件之间的接合部；在使用小于第一载荷的第二载荷使金属构件和树脂构件彼此压靠的同时，将接合部的温度保持在高于构成树脂构件的树脂的熔融温度的第一温度下；和在使用大于第二载荷的第三载荷使金属构件和树脂构件彼此压靠的同时，冷却接合部至低于所述熔融温度的第二温度。采用此结构，既可以抑制接合部中溢料的产生，又可以抑制因气泡所致的强度下降。
第一温度可低于树脂的分解温度。因此可以抑制因树脂的热分解所致的劣化。此外，当将接合部的温度保持在第一温度下时，压制部的位置可被固定。压制部为金属构件和树脂构件彼此压靠的部分。第三载荷可小于第一载荷。因此可以愈加抑制溢料的产生。可将接合部的温度在第一温度下保持30秒或更长时间。因此，施加到金属构件的极性官能团与树脂构件中所含的粘合性官能团之间的化学反应得以促进。
极性官能团可为羧基基团和氨基基团中的至少任一者，以及粘合性官能团可为环氧基团。金属构件的主要组分可为铝，树脂构件的主要组分可为聚苯硫醚。
根据本发明的一个方面的冷却器的制造方法包括以下构成。所述冷却器包括金属板和框架体。所述金属板在金属板的一侧上的主表面上具有冷却翅片。框架体容纳冷却翅片并在框架体内部一体地具有冷却剂流道。框架体由树脂制成。所述制造方法包括：向所述主表面上施加极性官能团，其中所述极性官能团与框架体中所含的粘合性官能团彼此吸引；在使用第一载荷使金属板和框架体彼此压靠的同时，加热金属板和框架体之间的接合部；在使用小于第一载荷的第二载荷使金属板和框架体彼此压靠的同时，将接合部的温度保持在高于构成框架体的树脂的熔融温度的第一温度下；和在使用大于第二载荷的第三载荷使金属板和框架体彼此压靠的同时，冷却接合部至低于所述熔融温度的第二温度。采用此结构，既可以抑制接合部中溢料的产生，又可以抑制因气泡所致的强度下降。
第一温度可低于树脂的分解温度。因此可以抑制因树脂的热分解所致的劣化。此外，当将接合部的温度保持在第一温度下时，压制部的位置可被固定。压制部为金属构件和树脂构件彼此压靠的部分。第三载荷可小于第一载荷。因此可以愈加抑制溢料的产生。可将接合部的温度在第一温度下保持30秒或更长时间。因此，施加到金属构件的极性官能团与树脂构件中所含的粘合性官能团之间的化学反应得以促进。
根据本发明的一个方面的冷却器具有以下构成。所述冷却器包括金属板和框架体。金属板包括在所述金属板的一侧上的主表面上的冷却翅片。框架体容纳冷却翅片并且在框架体内部一体地具有冷却剂流道。框架体由树脂制成。金属板在主表面上包含极性官能团。框架体包含粘合性官能团。粘合性官能团与极性官能团彼此吸引。在将金属板和框架体彼此接合时，在使用第一载荷使金属板和框架体彼此压靠的同时加热所述金属板和所述框架体之间的接合部。然后，在使用小于第一载荷的第二载荷使金属板和框架体彼此压靠的同时使接合部的温度保持在高于构成框架体的树脂的熔融温度的第一温度下。在使用大于所述第二载荷的第三载荷使金属板和框架体彼此压靠的同时冷却接合部至低于所述熔融温度的第二温度。采用此结构，既可以抑制接合部中溢料的产生，又可以抑制因气泡所致的强度下降。
附图说明
本发明的示例性实施方案的特征、优点以及技术和工业重要性将在下文结合附图描述，在附图中，相同的附图标记表示相同的要素，并且其中：
图1为示出了根据本发明的一个实施方案的接合装置的示意性剖视图；
图2为示出接合部的温度和下沉量的时间变化的图；
图3为在其中使接合部的温度保持在高于树脂熔融温度但低于树脂分解温度的状态下接合部的示意性剖视图；
图4为通过根据本发明的实施方案的方法制成的接合部的示意性剖视图；
图5为通过根据本发明的实施方案的方法制成的接合部的显微组织的照片；
图6为通过根据第一对比例的方法制成的接合部的显微组织的照片；
图7为通过根据本发明的实施方案的方法制成的接合部的宏观照片；
图8为通过根据第二对比例2的方法制成的接合部的宏观照片；
图9为用于检漏试验的试验件的透视图；
图10为用于检漏试验的试验机的剖视图；
图11为示出对接合部进行的氦气检漏试验的结果的图；
图12为通过采用根据本发明的实施方案的方法制造的冷却器的透视图；
图13为通过采用根据本发明的实施方案的方法制造的冷却器的顶视图；
图14为沿图13中的线XIV-XIV截取的剖视图；和
图15为沿图13中的线XV-XV截取的剖视图。
具体实施方式
下面结合附图详细说明应用本发明的一个具体实施方案。然而，这不应理解为本发明局限于下面的实施方案。为了使说明清晰，下面的描述和附图根据需要进行了简化。
首先，结合图1说明根据所述实施方案的接合装置。图1为示出了根据所述实施方案的接合装置的示意性剖视图。根据所述实施方案的接合装置为用于将金属构件1与树脂构件2接合的接合装置。
如图1中所示，根据所述实施方案的接合装置包括冷却面板101，绝缘板102a、102b，加热器103，电极104a、104b，压力板105和热电偶106。自然，为方便起见，使用图1中示出的右手xyz坐标系来解释位置关系。在图1中，xy平面构成水平面，z-轴正方向代表竖直向上方向。
冷却面板101为在其上布置加热器103的面板。冷却面板101还具有在使加热器103的通电停止时冷却加热器103的功能。冷却面板101内部形成有冷却水通道(未示出)，并且冷却面板101由具有优异导热性的金属如铜和铜合金制成。优选冷却面板101布置在水平面(xy平面)上。还优选其上布置有加热器103的冷却面板101的上表面为水平面(xy平面)。
绝缘板102a为用于使加热器103和金属冷却面板101彼此绝缘的片材。因此，绝缘板102a插入在加热器103和冷却面板101之间。在图1中示出的实例中，绝缘板102a设置在加热器103的整个下表面上。绝缘板102a可被固定到加热器103的下表面。由绝缘板102a防止加热器103中为加热而流动的电流流入冷却面板101中，从而提高加热器103的加热效率。
绝缘板102b为用于使加热器103和金属构件1彼此绝缘的片材。因此，绝缘板102b插入在加热器103和金属构件1之间。在图1中示出的实例中，绝缘板102a设置在加热器103的几乎整个上表面上。然而，绝缘板102a没有设置在加热器103的上表面沿x-轴方向的设置有电极104a、104b的两个端部上。绝缘板102a可被固定到加热器103的上表面。由绝缘板102b防止加热器103中为加热而流动的电流流入金属构件1中，从而提高加热器103的加热效率。
加热器103为板状电加热设备以加热板状金属构件1。具体而言，加热器103加热金属构件1并熔化布置在金属构件1上的树脂构件2的接合部。优选加热器103为例如电加热类型的碳加热器。通过使用对加热和冷却具有优异响应能力的碳加热器，可以精确地控制接合部的温度和加热时间。加热器103内部设置有热电偶106。热电偶106测量接合部附近的温度并对加热器103的加热进行反馈控制。
如上所述，加热器103通过绝缘板102a布置在冷却面板101上。同时，金属构件1通过绝缘板102b布置在加热器103上。此外，在加热器103的上表面沿x-轴方向负侧的端部上设置有凸部103a以提供电极104a。同时，在加热器103的上表面沿x-轴方向正侧的端部上设置有凸部103b以提供电极104b。如图1中所示，凸部103a和凸部103b形成为从其上沿z-轴方向正侧上布置有金属构件1的平坦部突起。
电极104a、104b为用于使加热器103通电的电极。电极104a设置在加热器103的凸部103a的上表面上。同时，电极104b设置在加热器103的凸部103b的上表面上。电极104a、104b二者均设置为凸出至加热器103的外侧。电极104a、104b中之一为正电极，而另一个为负电极，并且所述电极中的任一者可为正电极或负电极。换句话说，加热器103中流动的电流的方向不受限制。
压力板(压制部)105为板状构件，其能够沿z-轴方向移动并自上侧(沿z-轴方向正侧)向下(向着z-轴方向的负侧)压制树脂构件2。当使金属构件1和树脂构件2彼此接合时，金属构件1和树脂构件2通过压力板105彼此压靠，并由此紧密地粘附到彼此。伺服电机控制由压力板105对树脂构件2施加的载荷及压力板105沿z-轴方向的位移。
接下来，结合图1解释待彼此接合的金属构件1和树脂构件2。在图1中示出的实例中，金属构件1为平板状构件。树脂构件2为盒状构件，其底面是开口的。如图1中所示，其底面开口的树脂构件2被布置在金属构件1上，并且树脂构件2和金属构件1彼此接合。如此，获得其中树脂构件2的开口部被金属构件1覆盖的壳体。形成在通过使金属构件1与树脂构件2接合而获得的壳体的外部的溢料易于被移除。同时，难以移除形成在所述壳体的内部的溢料，这是一个问题。图1中示出的金属构件1和树脂构件2的形状仅为实例，而金属构件1和树脂构件2的形状根本不受限制。
构造金属构件1的金属的实例包括铝、铜、镍、锡、金、银、铁、镁、铬、钨、锌、铅以及这些金属的合金。优选含铝作为主要组分的金属构件1。
在接合之前向金属构件1的接合表面上施加极性官能团。极性官能团的实例包括羧基基团、氨基基团、羟基基团和醛基团。优选羧基基团或氨基基团，因为它们易于施加到金属部的表面上。
用于向金属构件1的接合表面上施加极性官能团的表面处理方法的实例包括涂布处理、火焰处理、气相沉积处理和等离子体处理，其中使用含极性官能团、其衍生物等的化合物。
含极性官能团或其衍生物的化合物的实例包括以下。含羧基基团的化合物的实例包括例如丙烯酸单体、丙烯酸聚合物、丙烯酸与马来酸的共聚物、甲基丙烯酸单体和甲基丙烯酸聚合物。含氨基基团的化合物的实例包括例如烯丙胺单体和烯丙胺聚合物。羧基基团和氨基基团的衍生物的实例包括例如己内酰胺和聚酰胺。
从耐热性的角度出发，构成树脂构件2的树脂的优选实例为工程塑料如聚苯硫醚(PPS)、聚酰胺(PA)和聚对苯二甲酸丁二醇酯(PBT)。当然，也可使用商品塑料如聚乙烯(PE)、聚丙烯(PP)、聚苯乙烯(PS)和聚氯乙烯(PVC)作为构成树脂构件2的树脂。
将含有与施加到金属构件1的接合表面上的上述极性官能团相互作用的粘合性官能团的粘合性改性剂与树脂构件2组合。粘合性改性剂的实例包括其中含有聚乙烯、聚苯乙烯等作为主链以及含有苯乙烯聚合物作为侧链的接枝共聚物经由粘合性官能团变性的化合物和其中聚乙烯、聚苯乙烯等经由粘合性官能团变性的化合物。具体实例包括经由甲基丙烯酸缩水甘油酯使乙烯与苯乙烯的共聚物变性而获得的变性乙烯-苯乙烯共聚物和经由甲基丙烯酸缩水甘油酯使聚乙烯变性而获得的变性聚乙烯。
对于100质量份的树脂和粘合性改性剂的总量，优选粘合性改性剂的含量为5-40质量份。当所述含量为5质量份或更少时，树脂构件2对金属构件1的粘附性减小。另一方面，当所述含量超过40质量份时，形成树脂构件2时的脱模特性劣化。更优选10-30质量份的含量。
粘合性改性剂中所含的粘合性官能团的实例包括环氧基团、羧基基团、氨基基团和羟基基团。粘合性官能团也可包含在缩水甘油基基团中。优选环氧基团，因为环氧基团易于与极性官能团反应。优选树脂与粘合性改性剂的混合物中粘合性官能团的含量为树脂与粘合性改性剂的总量的0.15-1.2质量％。当该值小于0.15质量％时，树脂构件2对金属构件1的粘附性减小。另一方面，当该值超过1.2质量％时，形成树脂构件2时的脱模特性劣化。更优选0.3-0.9质量％的值。
据认为，金属构件1与树脂构件2的接合界面上的粘附性是由施加到金属构件1的表面上的极性官能团与树脂构件2中所含的粘合性官能团之间的相互作用引起的。所述相互作用为其中极性官能团和粘合性官能团的原子、电子等在接合界面上彼此吸引的相互作用。所述相互作用的具体实例包括以下相互作用。第一实例为极性官能团与粘合性官能团的原子之间的电子转移和共享所伴随的主要键合(如离子键和共价键)。第二实例为其中电子密度在极性官能团与粘合性官能团内部不均匀分布并且两种官能团利用库仑力彼此吸引的辅助键合(如氢键和范德华键)。
接下来，参照图2解释根据所述实施方案的方法。图2为示出接合部的温度和下沉量的时间变化的图。在图2中，水平轴示出时间(秒)，左边的垂直轴示出温度(℃)，而右边的垂直轴示出下沉量(mm)。在图1中，下沉量表示直至从接合前其中金属构件1与树脂构件2彼此紧密接触的状态接合之后，例如树脂构件2的上表面向z-轴方向负侧移动的量。下沉量因主要在接合时接合部中的树脂构件2熔化并作为溢料自接合部排放而产生。因此，优选较小的下沉量。图2还示出了施加到树脂构件2的载荷及用于使加热器103通电的电流的时间变化。载荷和通电电流的单位可以是任意的。
在图2中示出的实例中，使用铝板作为金属构件1。将含氨基基团为极性官能团的水溶性聚丙烯胺施加在金属构件1的表面上，然后干燥。对于树脂构件2，使用PPS树脂，其中将含环氧基团为粘合性官能团的聚乙烯作为粘合性改性剂。对于100质量份的树脂和粘合性改性剂的总量，粘合性改性剂的含量为10质量份。树脂构件2的熔融温度为280℃并且树脂构件2的分解温度为350℃。
如图2中所示，首先向树脂构件2施加载荷L1以使待彼此接合的金属构件1和树脂构件2彼此紧密接触。在其中保持载荷L1的状态下，加热器103的通电开始并且接合部的升温。载荷L1为第一载荷的一个实例。
接下来，在接合部的温度达到树脂构件2的熔融温度之前，将向树脂构件2施加的载荷从L1减至L2。载荷L2为第二载荷的一个实例。在图2中示出的实例中，在当接合部的温度超过200℃时的点处，将向树脂构件2施加的载荷从L1减至L2。具体地，固定图1中压力板105的位置。随着升温，减小向树脂构件2施加的载荷。此外，由于接合部中树脂的熔化，几乎不施加载荷。换句话说，L2的值变为几乎0。其后，在当接合部的温度达到树脂构件2的熔融温度时的点处，略微减小通电电流并保持。由此，可以使接合部的温度在高于树脂构件2的熔融温度但低于树脂构件2的分解温度的温度下保持给定的时间段。
图3为保持在高于树脂熔融温度但低于树脂分解温度的温度下的接合部的示意性剖视图。由于接合部保持在高于树脂熔融温度的温度下，因而接合界面IF上的树脂构件2熔化(熔化部2a)，如图3中所示。因此，在接合界面IF中，施加到金属构件1的极性官能团与树脂构件2中所含粘合性官能团之间的化学反应得到促进。结果，金属构件1与树脂构件2刚性地彼此接合。同时，通过将接合部的温度保持为低于树脂分解温度，可以防止树脂构件2的强度因接合部中树脂的分解所致的下降。由于施加到树脂构件2的载荷L2小，因而下沉量保持为约0.05mm，如图2中所示。因此，如图3中所示，溢料的产生得以抑制。
如图2中所示，在接合部的温度保持给定的时间段后，结束加热器103的通电，接合部的温度下降开始。在此冷却过程中，向树脂构件2施加小于L1但大于L2的载荷L3。载荷L3为第三载荷的一个实例。因此，下沉量增至约0.1mm。换句话说，产生了溢料，但溢料的量小。然而，图3中所示熔化部2a中产生的气泡因载荷L3的施加而破碎。因此，可以防止树脂构件2的接合部的强度因树脂构件2中的气泡而下降。
当载荷小于L2时，气泡不会有效地破碎。另一方面，当载荷为L1或更大时，产生的溢料的量增大。增大载荷的优选时机为当温度开始下降(停止加热)时或以后。由此，溢料的产生得以抑制。同时，增大载荷的优选时机为接合部的温度变得低于树脂熔融温度之前。由此，有效地使气泡破碎。载荷L1-L3不必为恒定的值。
图4为通过根据实施方案的方法制成的接合部的示意性剖视图。如图4中所示，在接合界面IF附近的树脂构件2中产生的气泡消失，并且溢料2b的产生得以抑制。
图5为通过根据本发明的实施方案的方法制成的接合部的显微组织的照片。如图5中所示，在接合界面IF附近的树脂构件2中确认没有气泡。图6为通过根据第一对比例的方法制成的接合部的显微组织的照片。在第一对比例1中，冷却过程中载荷不从L2增至L3而是保持在L2。如图6中所示，在第一对比例中，在接合界面IF附近的树脂构件2中确认有气泡。
图7为通过根据本发明的实施方案的方法制成的接合部的宏观照片。如图7中所示，溢料2b自树脂构件2的产生得以抑制。优选溢料2b的突出量为树脂构件2的宽度的一半或更小。在图7中的实例中，自宽度为4.0mm的树脂构件2产生最大突出量为1.8mm的溢料2b。
图8为通过根据第二对比例的方法制成的接合部的宏观照片。在第二对比例中，在保持接合部的温度时不将载荷从L1减至L2而是保持在L1。如图8中所示，自树脂构件2产生大量的溢料2b。在图8中示出的实例中，自宽度为4.0mm的树脂构件2产生最大突出量为4.8mm的溢料2b。
接下来，参照图9至图11解释图2中斜线所示接合部的熔体保持时间和峰值温度的条件。为了研究该条件，对采用不同的熔体保持时间和峰值温度接合的试验件进行氦气检漏试验。
图9为用于检漏试验的试验件的透视图。如图9中所示，用于检漏试验的试验件通过用根据实施方案的方法将铝板T1与PPS树脂板T2接合来获得，所述方法已参照图2加以解释。铝板T1对应于图1中的金属构件1，PPS树脂板T2对应于图1中的树脂构件2。接合盘状PPS树脂板T2以覆盖矩形铝板T1的中心部中形成的开口部T1a。如此形成甜甜图形状的接合部(接合界面IF)。与图2的情况类似，接合之前向铝板T1的表面上施加作为极性官能团的氨基基团。将环氧基团作为粘合性官能团与PPS树脂板T2组合。
图10为用于检漏试验的试验机的剖视图。如图10中所示，用于检漏试验的试验机包括其中设置有真空排气路径的上堵块BL1和其中设置有氦气引入路径的下堵块BL2。通过O形环OR1、OR2将用于检漏试验的试验件的铝板T1包夹在上堵块BL1和下堵块BL2之间。
当用于检漏试验的试验件的接合部不完好时，自下堵块BL2引入的氦气通过开口部T1a和铝板T1的接合部自上堵块BL1排放。因此，检测从接合部泄漏的氦气。同时，当用于检漏试验的试验件的接合部是完好的时，自下堵块BL2引入的氦气由接合部堰塞，而排放侧上检测不到氦气。
图11为示出接合部的氦气检漏试验的结果的图。水平轴示出保持树脂熔融温度或更高温度的时间(熔体保持时间)(s)，垂直轴示出接合部的峰值温度(℃)。如图11中所示，使熔体保持时间变为10s、20s、30s、40s、110s和180s。使峰值温度从树脂熔融温度(280℃)变为±0℃、+15℃、+30℃、+60℃和+90℃。按顺序解释在每一峰值温度下的试验结果。
当峰值温度为±0℃时，在使用20s、30s、40s、110s和180s的熔体保持时间的所有经受检漏试验的样品中均确认有泄漏。当峰值温度为±0℃时，接合部的温度低，推测施加到铝板T1的极性官能团与PPS树脂板T2中所含的粘合性官能团之间的化学反应变得不充分。
当峰值温度为+15℃时，在使用30s和40s的熔体保持时间测试的样品中确认有泄漏。另一方面，在使用110s和180s的熔体保持时间测试的样品中未确认有泄漏。当峰值温度为+15℃且熔体保持时间为40s或更短时，施加到铝板T1的极性官能团与PPS树脂板T2中所含的粘合性官能团的反应时间短，推测极性官能团与粘合性官能团之间的化学反应变得不充分。同时，当熔体保持时间为110s或更长时，推测施加到铝板T1的极性官能团与PPS树脂板T2中所含的粘合性官能团之间的化学反应得以充分促进。
当峰值温度为+30℃时，在使用10s和20s的熔体保持时间测试的样品中确认有泄漏。另一方面，在使用30s、40s、110s和180s的熔体保持时间测试的样品中未确认有泄漏。当峰值温度为+30℃且熔体保持时间为20s或更短时，施加到铝板T1的极性官能团与PPS树脂板T2中所含的粘合性官能团的反应时间短，推测极性官能团与粘合性官能团之间的化学反应变得不充分。同时，当熔体保持时间为30s或更长时，推测施加到铝板T1的极性官能团与PPS树脂板T2中所含的粘合性官能团之间的化学反应得以充分促进。
当峰值温度为+60℃时，在使用20s的熔体保持时间测试的样品中确认有泄漏。同时，在使用30s、40s、110s和180s的熔体保持时间测试的样品中未确认有泄漏。与其中峰值温度为+30℃的情况类似，当峰值温度为+60℃且熔体保持时间为20s以及更短时，施加到铝板T1的极性官能团与PPS树脂板T2中所含的粘合性官能团的反应时间短，推测极性官能团与粘合性官能团之间的化学反应变得不充分。同时，当熔体保持时间为30s或更长时，推测施加到铝板T1的极性官能团与PPS树脂板T2中所含的粘合性官能团之间的化学反应得以充分促进。
当峰值温度为+90℃时，仅对使用30s的熔体保持时间的样品进行了试验并确认有泄漏。当峰值温度为+90℃且熔体保持时间为30s时，推测施加到铝板T1的极性官能团与PPS树脂板T2中所含粘合性官能团之间的化学反应得以充分促进，并且接合界面IF上铝板T1与PPS树脂板T2之间的粘附性得以确保。然而，由于峰值温度高于树脂分解温度(+70℃)，推测接合部中熔化的树脂被热分解，并且接合部中树脂的强度下降。
从上面的结果，优选在根据所述实施方案的方法中使接合部的温度保持高于树脂熔融温度但低于树脂分解温度达30秒或更长。如此可以充分地促进施加到金属构件1的极性官能团与树脂构件2中所含的粘合性官能团之间的化学反应，并且还可以防止树脂构件2的强度因热分解而下降。
如上文所解释，在根据所述实施方案的方法中，使在保持接合部的温度高于树脂熔融温度的过程(保温过程)中向树脂构件2施加的载荷减至小于在升温过程中施加的载荷。因此，可以抑制接合部中溢料的产生。在升温过程中，使向树脂构件2施加的载荷增至大于在保温过程中的载荷。如此有效地使因树脂的熔化所产生的气泡破碎并消失。结果，可以抑制接合部中溢料的产生及因气泡所致的强度下降。
接下来，结合图12至图15解释通过采用根据所述实施方案的方法制造的冷却器。图12为通过采用根据所述实施方案的方法制造的冷却器的透视图。具体地，图12为自斜下方观察冷却器的透视图。图13为通过采用根据所述实施方案的方法制造的冷却器的顶视图。图13示出了其中移除了图12中所示的冷却构件10的状态。图14为沿着图13中的线XIV-XIV截取的剖视图。图15为沿着图13中的线XV-XV截取的剖视图。为方便起见，使用图12至图15中示出的右手xyz坐标系来解释位置关系。在图12至图15中，xy平面构成水平面，而z-轴正方向代表竖直向上方向。
如图12中所示，根据所述实施方案的冷却器包括金属冷却构件10、由树脂制成的流路构成构件20和金属底板30。冷却构件10包括顶板11和冷却翅片12。流路构成构件20包括框架体21和分隔板22。在图12中，流路构成构件20和底板30被部分切割，切割面以阴影线表示。
如图12中所示，顶板11为矩形金属板，其中xy平面充当主表面且x-轴方向充当纵向。在顶板11的上表面(沿z-轴方向正侧上的主表面)上放置待冷却的物体(未示出)如半导体晶片。同时，在顶板11的下表面(沿z-轴方向负侧上的主表面)上布置多个冷却翅片12以向下突出(向着z-轴方向的负侧)。优选顶板11和冷却翅片12彼此一体式地形成。
如图12中所示，在顶板11的下表面上布置的多个冷却翅片12为具有相同形状的矩形金属板，并且在每一冷却翅片12中，yz平面充当主表面且y-轴方向充当纵向。冷却翅片12设置为几乎彼此平行并且在顶板11的纵向(沿x-轴方向)上间隔相等。如图13中所示，每一个冷却翅片12布置为使得冷却翅片12的两端均与框架体21接触。在图13中，冷却翅片12由虚线表示。
如图13中所示，框架体21与顶板11和底板30一起构成冷却器的壳体。如图14中所示，在框架体21沿x-轴方向负侧上的端面(yz平面)上布置有冷却剂供给端口25。供给端口25布置在分隔板22的下侧上(z-轴方向的负侧上)。同时，在框架体21沿x-轴方向正侧上的端面(yz平面)上布置有冷却剂排放端口26。排放端口26布置在分隔板22的上侧(z-轴方向的正侧)上。
如图12和图13中所示，分隔板22是与框架体21一体式地形成的板状构件。分隔板22布置为与顶板11和底板30平行。冷却剂的供给通道和排放通道用分隔板22分隔。具体地，分隔板22的下侧为供给通道，分隔板22的上侧为排放通道。在分隔板22中布置有喷嘴23，喷嘴23向上(沿z-轴正方向)突出并沿x-轴方向延伸。冷却剂由喷嘴23供给到冷却翅片12。此外，相邻喷嘴23之间的空间构成排气通道24。供给通道和排气通道24通过喷嘴23彼此连接。
接下来，结合图14和图15解释冷却剂的流动。图14和图15中的箭头示出了冷却剂的流动。首先，如图14中所示，自供给端口25供给的冷却剂在分隔板22的下侧上的供给通道中流向x-轴方向的正侧。接下来，如图14和图15中所示，冷却剂沿z-轴正方向自喷嘴23流动并在相邻的冷却翅片12之间流动。然后，如图14和图15中所示，冷却剂在相邻的冷却翅片12之间流向y-轴方向的正侧或负侧，流向z-轴方向的负侧，然后流入排气通道24中。最后，如图14中所示，冷却剂在排气通道24中流向x-轴方向的正侧，并且自排放端口26排放。
接下来，解释冷却器的制造方法。首先，通过根据所述实施方案的方法将金属冷却构件10的下表面和由树脂制成的流路构成构件20的上表面彼此接合。具体而言，将顶板11的下表面的周缘与框架体21的上表面彼此接合。顶板11对应于图1中所示金属构件1，框架体21对应于图1中所示的树脂构件2。在图1中，顶板11布置在加热器103上使得顶板11的下表面朝上，框架体21布置在顶板11上使得框架体21的上表面朝下。方法的细节与上面的解释相同并因此略去。
接下来，通过使用根据所述实施方案的方法将金属底板30的上表面和由树脂制成的流路构成构件20的下表面彼此接合。具体地，将底板30的上表面的周缘与框架体21的下表面彼此接合。这里，底板30对应于图1中的金属构件1，框架体21对应于图1中的树脂构件2。在图1中，底板30布置在加热器103上使得底板30的上表面朝上，框架体21布置在底板30上使得框架体21的下表面朝下。方法的细节与上面的解释相同并因此略去。自然地，在将冷却构件10和流路构成构件20彼此接合之前可以将底板30和流路构成构件20彼此接合。
采用上述制造方法，可以抑制溢料的产生和因冷却构件10或底板30与流路构成构件20的接合部中的气泡所致的强度下降。换句话说，可以获得具有优异的冷却性能和冷却剂密封性的冷却器。形成在冷却器外部的溢料易于移除。另一方面，难以移除形成在冷却器内部的溢料，这可能导致问题，因为溢料阻断冷却剂的流动。
本发明不限于前述实施方案，并且可根据需要进行改变而不偏离本发明的主旨。例如，冷却器的底板30可由树脂制成并且与流路构成构件20一体式地形成。

Claims (13)

1.一种将金属构件和树脂构件彼此接合的方法，所述金属构件的表面上施加有极性官能团，所述树脂构件含有粘合性官能团，所述粘合性官能团和所述极性官能团彼此吸引，所述方法包括：
在使用第一载荷使所述金属构件和所述树脂构件彼此压靠的同时，加热所述金属构件和所述树脂构件之间的接合部；
在使用小于所述第一载荷的第二载荷使所述金属构件和所述树脂构件彼此压靠的同时，将所述接合部的温度保持在高于构成所述树脂构件的树脂的熔融温度的第一温度下；和
在使用大于所述第二载荷的第三载荷使所述金属构件和所述树脂构件彼此压靠的同时，冷却所述接合部至低于所述熔融温度的第二温度。
2.根据权利要求1所述的方法，其中所述第一温度低于所述树脂的分解温度。
3.根据权利要求1或2所述的方法，其中当将所述接合部的温度保持在所述第一温度下时使压制部的位置固定，以及
所述压制部为所述金属构件和所述树脂构件彼此压靠的部分。
4.根据权利要求1至3中任一项所述的方法，其中所述第三载荷小于所述第一载荷。
5.根据权利要求1至4中任一项所述的方法，其中将所述接合部的温度在所述第一温度下保持30秒或更长时间。
6.根据权利要求1至5中任一项所述的方法，其中
所述极性官能团为羧基基团和氨基基团中的至少任一者，和
所述粘合性官能团为环氧基团。
7.根据权利要求1至6中任一项所述的方法，其中
所述金属构件的主要组分为铝，和
所述树脂构件的主要组分为聚苯硫醚。
8.一种冷却器的制造方法，所述冷却器包括金属板和框架体，所述金属板在所述金属板的一侧上的主表面上具有冷却翅片，所述框架体容纳所述冷却翅片，所述框架体在所述框架体内部一体地具有冷却剂流道，所述框架体由树脂制成，所述制造方法包括：
向所述金属板的所述主表面上施加极性官能团，其中所述极性官能团和所述框架体中所含的粘合性官能团彼此吸引；
在使用第一载荷使所述金属板和所述框架体彼此压靠的同时，加热所述金属板和所述框架体之间的接合部；
在使用小于所述第一载荷的第二载荷使所述金属板和所述框架体彼此压靠的同时，将所述接合部的温度保持在高于构成所述框架体的树脂的熔融温度的第一温度下；和
在使用大于所述第二载荷的第三载荷使所述金属板和所述框架体彼此压靠的同时，冷却所述接合部至低于所述熔融温度的第二温度。
9.根据权利要求8所述的制造方法，其中所述第一温度低于所述树脂的分解温度。
10.根据权利要求8或9所述的制造方法，其中当将所述接合部的温度保持在所述第一温度下时使压制部的位置固定，以及
所述压制部为所述金属板和所述框架体彼此压靠的部分。
11.根据权利要求8至10中任一项所述的制造方法，其中所述第三载荷小于所述第一载荷。
12.根据权利要求8至11中任一项所述的制造方法，其中将所述接合部的温度在所述第一温度下保持30秒或更长时间。
13.一种冷却器，包括：
金属板，所述金属板包括在所述金属板的一侧上的主表面上的冷却翅片，所述主表面上具有极性官能团；和
框架体，所述框架体容纳所述冷却翅片，所述框架体在所述框架体内部一体地具有冷却剂流道，所述框架体由树脂制成，所述框架体含有粘合性官能团，所述粘合性官能团和所述极性官能团彼此吸引，所述金属板和所述框架体彼此接合，当将所述板和所述框架体彼此接合时，在使用第一载荷使所述金属板和所述框架体彼此压靠的同时加热所述金属板和所述框架体之间的接合部，在使用小于所述第一载荷的第二载荷使所述金属板和所述框架体彼此压靠的同时使所述接合部的温度保持在高于构成所述框架体的树脂的熔融温度的第一温度下，以及在使用大于所述第二载荷的第三载荷使所述金属板和所述框架体彼此压靠的同时冷却所述接合部至低于所述熔融温度的第二温度。
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