CN106232325B - 气体透过构件及其制造方法 - Google Patents

气体透过构件及其制造方法 Download PDF

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Publication number
CN106232325B
CN106232325B CN201580020284.3A CN201580020284A CN106232325B CN 106232325 B CN106232325 B CN 106232325B CN 201580020284 A CN201580020284 A CN 201580020284A CN 106232325 B CN106232325 B CN 106232325B
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Prior art keywords
gas permeable
resin component
permeable member
fluororesin
welding
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CN201580020284.3A
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CN106232325A (zh
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石井恭子
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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • 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
    • 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
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap 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
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • 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
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/23—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations
    • B29C66/232—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations said joint lines being multiple and parallel, i.e. the joint being formed by several parallel joint lines
    • 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
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/24—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight
    • B29C66/242—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours
    • B29C66/2422—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being circular, oval or elliptical
    • B29C66/24221—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being circular, oval or elliptical being circular
    • 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
    • B29C66/532—Joining single elements to the wall of tubular articles, hollow articles or bars
    • B29C66/5326—Joining single elements to the wall of tubular articles, hollow articles or bars said single elements being substantially flat
    • 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
    • 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
    • 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
    • B29C66/72—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
    • 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
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    • B29C66/7311—Thermal properties
    • B29C66/73115—Melting point
    • B29C66/73116—Melting point of different melting point, i.e. the melting point of one of the parts to be joined being different from the melting point 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
    • B29C66/731—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 intensive physical properties of the material of the parts to be joined
    • B29C66/7318—Permeability to gases or liquids
    • B29C66/73181—Permeability to gases or liquids permeable
    • B29C66/73182—Permeability to gases or liquids permeable to gases
    • 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
    • B29C66/735—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 extensive physical properties of the parts to be joined
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B29C66/7392—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
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
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  • Thermal Sciences (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Fluid Mechanics (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Separation Using Semi-Permeable Membranes (AREA)
  • Arrangement Of Elements, Cooling, Sealing, Or The Like Of Lighting Devices (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)

Abstract

使用在应与加工对象相接的作用面(62p)上设有凸部(62t)的熔敷焊头(62)，将由氟树脂制成的气体透过性的氟树脂多孔质膜(4)熔敷于由热塑性树脂制成的树脂零件(2)。在熔敷焊头(62)的作用面(62p)上设有例如多个凸部(62t)。多个凸部(62t)也可以在作用面(62p)上排列成格子状。

Description

气体透过构件及其制造方法
技术领域
本发明涉及通气构件、防水通音构件等气体透过构件及其制造方法。
背景技术
在用于收容灯、传感器、ECU(electronic control unit：电子控制单元)等的汽车的电气零件的壳体上安装有用于确保壳体的内部与外部的通气并阻止异物向壳体的内部的侵入的通气构件。例如，专利文献1记载了在车辆用灯外壳的开口部粘结或熔敷气体透过膜的情况。
作为将气体透过膜固定于灯外壳等树脂零件的方法，专利文献1公开了粘结及熔敷。粘结虽然是简单的方法，但是存在生产性不太好的情况、粘结强度时效性地下降的情况等问题。另一方面，熔敷存在材料的相容性的问题。尤其是气体透过膜由氟树脂制成且树脂零件由热塑性树脂制成时，将气体透过膜向树脂零件熔敷的情况并不容易。因此，在以往的树脂零件的表面设有熔敷肋。通过一边将气体透过膜向树脂零件的表面的熔敷肋压紧一边使熔敷肋熔融及固化，能够提高树脂零件与气体透过膜之间的熔敷强度(专利文献2)。
在先技术文献
专利文献
专利文献1：日本特开2006-324260号公报
专利文献2：日本特开2009-078866号公报
发明内容
发明要解决的课题
根据专利文献2的方法，虽然能够期待熔敷强度的提高，但是在树脂零件中，熔敷肋不可或缺。希望一种不依赖于熔敷肋而能够实现充分的熔敷强度的技术。
本发明的目的在于提高树脂零件与树脂膜之间的熔敷强度。
用于解决课题的方案
即，本公开提供一种气体透过构件的制造方法，其中，
所述气体透过构件的制造方法包括如下工序：使用在应与加工对象相接的作用面上设置有凸部的熔敷焊头，将由氟树脂制成的气体透过性的氟树脂多孔质膜熔敷于由热塑性树脂制成的树脂零件。
在另一方案中，本公开提供一种气体透过构件，具备：
由热塑性树脂制成的树脂零件；及
安装于所述树脂零件且由氟树脂制成的气体透过性的氟树脂多孔质膜，
所述氟树脂多孔质膜使用在应与加工对象相接的作用面上设置有凸部的熔敷焊头而熔敷于所述树脂零件。
发明效果
在上述的技术中，在树脂零件上熔敷气体透过性的氟树脂多孔质膜。在熔敷焊头的作用面上设置凸部。因此，容易使来自熔敷焊头的载荷集中于氟树脂多孔质膜与树脂零件的界面。其结果是，能够容易地提高树脂零件与氟树脂多孔质膜之间的熔敷强度。
附图说明
图1是本发明的第一实施方式的通气构件的纵向剖视图。
图2是图1所示的通气构件的制造所使用的超声波熔敷装置的构成图。
图3是熔敷焊头的作用面的俯视图。
图4是另一熔敷焊头的剖视图及俯视图。
图5A是具备本发明的第二实施方式的通气构件(设有气体透过膜的盖部分)的壳体的立体图。
图5B是图5A所示的壳体的局部剖视图。
具体实施方式
以下，关于本发明的实施方式，参照附图进行说明。本发明没有限定为以下的实施方式。
(第一实施方式)
如图1所示，本实施方式的通气构件10具备支承体2、气体透过膜4、罩盖6及密封环8。通气构件10例如安装于壳体20(详细而言为壳体的盖部分)的开口部20h。利用通气构件10及壳体20形成通气构造100。
壳体20是为了收容电气零件及/或机械零件而使用的壳体。壳体20典型地是灯、电动机、传感器、开关、ECU、齿轮箱等汽车零件的壳体。壳体20也可以使用作为用于收容电子公告板、道路标识等的汽车零件以外的零件的壳体。通气构件10是用于防止液体及固体的侵入并进行壳体20的内部的换气的构件。气体透过膜4容许壳体20的内部空间22与外部空间24之间的气体的流通，另一方面，防止液体及固体向内部空间22的侵入。
在本实施方式中，支承体2是由热塑性树脂制成的树脂零件。气体透过膜4是由氟树脂制成的气体透过性的氟树脂多孔质膜。在本实施方式中，气体透过膜4不具有加强材料等，仅由氟树脂多孔质膜构成。热塑性树脂具有相对低的熔点，氟树脂具有相对高的熔点。支承体2具有作为通气路径的贯通孔2h。以闭塞贯通孔2h的方式在支承体2的上表面熔敷气体透过膜4。在支承体2与气体透过膜4之间形成有熔敷部14，所述熔敷部14是构成支承体2的热塑性树脂通过熔融及固化而形成的熔敷部。熔敷部14例如俯视观察下为环形状。
作为构成支承体2的热塑性树脂，可列举聚丙烯、聚对苯二甲酸丁二醇酯、丙烯腈-丁二烯-苯乙烯共聚物、聚碳酸酯等。这些热塑性树脂的熔点大致为100～200℃。构成支承体2的热塑性树脂也可以包含玻璃纤维等添加剂。作为构成气体透过膜4的氟树脂，可列举聚四氟乙烯(PTFE)、聚三氟氯乙烯、四氟乙烯-六氟丙烯共聚物、四氟乙烯-乙烯共聚物等。这些氟树脂的熔点大致为250～350℃。气体透过膜4的厚度没有特别限定，例如为0.1～0.5mm。如第二实施方式那样气体透过膜4未由罩盖等保护的情况下，推荐气体透过膜4比较厚的情况(例如，0.2～0.4mm)。薄的氟树脂膜或者由薄的氟树脂膜和加强材料构成的膜那样的薄的气体透过膜4容易传递热量及振动，因此容易熔敷。另一方面，厚的气体透过膜4难以传递热量及振动，难以熔敷，因此特别推荐应用本说明书记载的技术。
罩盖6以保护气体透过膜4的方式安装于支承体2。罩盖6可以由与支承体2相同的材料制成，也可以由与支承体2不同的材料制成。
支承体2具有多个腿部12。在通气构造100中，支承体2的腿部12嵌入壳体20的开口部20h。腿部12卡合于壳体20的内表面。由此，通气构件10被固定于壳体20。密封环8配置在支承体2的下表面与壳体20的外表面之间。利用密封环8将支承体2与壳体20之间的间隙密封。密封环8例如由丁腈橡胶、乙丙橡胶、硅橡胶、氟橡胶、丙烯酸酯橡胶氢化丁腈橡胶等弹性体制成。
壳体20由多个部分例如盖部分和底部分构成。用于安装通气构件10的开口部20h也可以形成在任意的部分。壳体20例如由树脂制成。但是，在本实施方式中，壳体20的材料没有限定。壳体20也可以由金属制成。
接下来，说明图1所示的通气构件10的制造方法。
首先，准备支承体2、气体透过膜4及罩盖6。支承体2及罩盖6能够利用注塑成形法等公知的树脂成形方法来制成。作为气体透过膜4的氟树脂膜能够利用延伸法、抽出法等公知的氟树脂成形方法来制成。作为气体透过膜4而优选的PTFE多孔质膜例如能够从日东电工公司获得。
接下来，将气体透过膜4熔敷于支承体2。在该工序中，可以使用图2所示的熔敷装置300。在本实施方式中，熔敷装置300是超声波熔敷装置，具备固定台60、熔敷焊头62、超声波振子64、液压缸65、空气压缩器66、超声波振荡器67及控制器68。即，熔敷焊头62可以是超声波熔敷用的熔敷焊头。超声波熔敷能够高生产性地实现高强度的熔敷。熔敷装置300的结构除了熔敷焊头62之外，与市售的超声波熔敷装置相同。
在固定台60上为了熔敷气体透过膜4而配置支承体2(树脂零件)。液压缸65利用由空气压缩器66生成的压缩空气，使熔敷焊头62及超声波振子64接近气体透过膜4，并调节从熔敷焊头62向气体透过膜4施加的压力。控制器68控制超声波振荡器67，为了经由超声波振子64向熔敷焊头62施加而调节超声波振动的频率。
在本实施方式中，熔敷焊头62是在应与作为加工对象的气体透过膜4相接的作用面62p上设有凸部62t的熔敷焊头。因此，容易使来自熔敷焊头62的载荷集中于气体透过膜4与支承体2的界面。其结果是，能够容易地提高支承体2与气体透过膜4之间的熔敷强度。熔敷焊头62例如由铝合金、钛合金等金属制成。
如图3所示，熔敷焊头62的作用面62p在俯视观察下为环状。在作用面62p设有多个凸部62t。多个凸部62t在作用面62p上排列成格子状(网纹状)。各个凸部62t具有四角锥的形状。换言之，凸部62t具有俯视观察下为正方形的形状。这样的凸部62t无间隙(最紧密)地排列于作用面62p。根据这样的结构，容易使来自熔敷焊头62的载荷集中于气体透过膜4与支承体2的界面。而且，能够容易地提高支承体2与气体透过膜4之间的熔敷强度。
也可以取代图3所示的熔敷焊头62而使用图4所示的熔敷焊头72。熔敷焊头72的作用面72p在俯视观察下为环状(圆环状)。在作用面72p设有2个凸部72t。各凸部72t在俯视观察下为与作用面72p同心状的环状。利用这样的凸部72t，也容易使来自熔敷焊头72的载荷集中于气体透过膜4与支承体2的界面。凸部72t的个数没有限定为2个。凸部72t也可以在作用面72p上仅设置1个，还可以设置3个以上。
从图3及图4的例子可知，根据气体透过膜4的厚度、支承体2的树脂的种类等，可以适当变更熔敷焊头的作用面的凸部的形状。
需要说明的是，为了将气体透过膜4熔敷于支承体2，也可以取代超声波熔敷装置300而使用热熔敷装置。通常，在超声波熔敷装置中，树脂零件(支承体2)的一部分因摩擦热而熔化。在热熔敷装置中，树脂零件的一部分因熔敷焊头具有的热量而熔化。若将超声波振子64置换为加热器并将超声波振荡器67及控制器68置换为温度调节器，则图2示出热熔敷装置的结构。熔敷焊头62可以是热熔敷用的熔敷焊头。
接下来，说明第二实施方式的气体透过构件。在第一实施方式和第二实施方式中对于共通的要素标注相同的参照标号，有时省略它们的说明。即，关于各实施方式的说明只要在技术上不相矛盾，就可以相互适用。此外，只要在技术上不相矛盾，各实施方式也可以相互组合。
(第二实施方式)
如图5A及图5B所示，气体透过膜4也可以设于壳体200。壳体200由包含第一部分20及第二部分26的多个部分构成。例如，第一部分20为盖部分，第二部分26为底部分。第一部分20及第二部分26与第一实施方式的通气构件10的支承体2同样地由热塑性树脂制成。在本实施方式中，在第一部分20形成通气用的开口部20h。以闭塞开口部20h的方式在第一部分20熔敷气体透过膜4。通气用的开口部20h也可以形成于第二部分26，还可以形成于第一部分20及第二部分26这两方。壳体200的第一部分20及气体透过膜4形成用于防止液体及固体的透过并进行换气的通气构件30(气体透过构件)。
如图5B所示，在气体透过膜4与壳体200的第一部分20之间形成熔敷部14。熔敷部14在俯视观察下为环状。在本实施方式中，气体透过膜4使用参照图3或图4说明的熔敷焊头62或72而熔敷于壳体200的第一部分20。
(其他)
在各实施方式中，在熔敷气体透过膜4之前的树脂零件(支承体2或壳体的第一部分20)的上表面未设置用于提高熔敷强度的肋。但是，在树脂零件的上表面也可以设置这样的肋。
另外，在各实施方式中，气体透过膜4担当壳体的换气及内压调整的作用。即，气体透过膜4是通气膜。然而，气体透过膜4没有限定为通气膜。应通过本说明书公开的方法制造的气体透过构件也可以是用于防止水的透过并使声音透过的防水通音构件。包含气体透过膜4的防水通音构件例如设置于移动电话等通信设备的接听口及通话口。
【实施例】
(实施例)
准备了由包含30质量％的玻璃纤维及70质量％的聚对苯二甲酸丁二醇酯的树脂材料制成的壳体零件(ECU壳体的盖部分：参照图5A)。在壳体零件上形成了直径5mm的开口部之后，使用超声波熔敷装置(静电舍公司制，小型精密冲压机系列)，以堵塞开口部的方式，将PTFE多孔质膜(日东电工公司制，NTF810A，厚度0.3mm，直径10mm)熔敷于壳体零件。超声波的频率为28.5kHz，熔敷时间为0.16秒，熔敷压力(气压)为0.15MPa。作为熔敷焊头，使用了具有参照图2及图3说明的构造的结构。这样，得到了由PTFE多孔质膜及壳体零件构成的实施例的通气构件。
(比较例)
除了使用作用面平坦的熔敷焊头之外，以与实施例相同的条件尝试了在壳体零件的开口部熔敷PTFE多孔质膜的情况。然而，PTFE多孔质膜未熔敷于壳体零件，从壳体零件能简单地剥落。
[耐水试验]
根据日本工业标准JIS L 1092(B法，高水压法)，研究了实施例的通气构件的耐水压。具体而言，测定了发生漏水的水压(耐水压)。结果在表1中示出。如表1所示，实施例的通气构件实现了充分的耐水压。需要说明的是，在如实施例那样能够将PTFE多孔质膜没有问题地熔敷于壳体零件的情况下，将熔敷结果判断为“良好”。如比较例那样无法将PTFE多孔质膜熔敷于壳体零件的情况下，将熔敷结果判断为“不良”。
【表1】
Figure BDA0001132483550000081
工业实用性
本说明书公开的技术能够应用于通气构件、防水通音构件等气体透过构件的制造。

Claims (8)

1.一种气体透过构件的制造方法，其中，
所述气体透过构件的制造方法包括如下工序：使用在应与加工对象相接的作用面上设置有多个凸部的熔敷焊头，将由熔点为250～350℃的范围的氟树脂制成的气体透过性的氟树脂多孔质膜熔敷于由熔点为100～200℃的范围的热塑性树脂制成的树脂零件，
所述树脂零件是在用于进行壳体内部的换气的通气构件中使用的支承体、在用于防止水的透过并使声音透过的防水通音构件中使用的支承体、或者壳体的一部分，
所述熔敷焊头通过使所述树脂零件的所述热塑性树脂熔融及固化而在所述树脂零件与所述氟树脂多孔质膜之间形成熔敷部。
2.根据权利要求1所述的气体透过构件的制造方法，其中，
所述多个凸部中的各个凸部具有四角锥的形状，
所述多个凸部在所述作用面上排列成最紧密且格子状。
3.根据权利要求1所述的气体透过构件的制造方法，其中，
所述作用面在俯视观察下为环状，
所述凸部在俯视观察下为与所述作用面同心状的环状。
4.根据权利要求1所述的气体透过构件的制造方法，其中，
所述熔敷焊头是超声波熔敷用的熔敷焊头。
5.根据权利要求1所述的气体透过构件的制造方法，其中，
所述气体透过构件是(a)用于防止液体及固体的透过并进行换气的通气构件，或者是(b)用于防止水的透过并使声音透过的防水通音构件。
6.根据权利要求1所述的气体透过构件的制造方法，其中，
构成所述树脂零件的所述热塑性树脂是由聚丙烯、聚对苯二甲酸丁二醇酯、丙烯腈-丁二烯-苯乙烯共聚物、以及聚碳酸酯所构成的组中选择的一个。
7.根据权利要求1所述的气体透过构件的制造方法，其中，
构成所述氟树脂多孔质膜的所述氟树脂是由聚四氟乙烯、聚三氟氯乙烯、四氟乙烯-六氟丙烯共聚物、以及四氟乙烯-乙烯共聚物所构成的组中选择的一个。
8.一种气体透过构件，具备：
由熔点为100～200℃的范围的热塑性树脂制成的树脂零件；及
安装于所述树脂零件且由熔点为250～350℃的范围的氟树脂制成的气体透过性的氟树脂多孔质膜，
所述氟树脂多孔质膜使用在应与加工对象相接的作用面上设置有多个凸部的熔敷焊头而熔敷于所述树脂零件，
所述树脂零件是在用于进行壳体内部的换气的通气构件中使用的支承体、在用于防止水的透过并使声音透过的防水通音构件中使用的支承体、或者壳体的一部分，
通过所述树脂零件的所述热塑性树脂熔融及固化而在所述树脂零件与所述氟树脂多孔质膜之间形成熔敷部。
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