CN106573342A - 接合结构体的制造方法以及接合结构体 - Google Patents

接合结构体的制造方法以及接合结构体 Download PDF

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Publication number
CN106573342A
CN106573342A CN201580040009.8A CN201580040009A CN106573342A CN 106573342 A CN106573342 A CN 106573342A CN 201580040009 A CN201580040009 A CN 201580040009A CN 106573342 A CN106573342 A CN 106573342A
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CN
China
Prior art keywords
component
bonded structure
perforated portion
laser
manufacture method
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Pending
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CN201580040009.8A
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English (en)
Inventor
西川和义
角谷彰朗
广野聡
博田知之
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Omron Corp
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Omron Corp
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Publication of CN106573342A publication Critical patent/CN106573342A/zh
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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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14311—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles
    • 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
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/0078—Measures or configurations for obtaining anchoring effects in the contact areas between layers
    • B29C37/0082—Mechanical anchoring
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/0006—Working by laser beam, e.g. welding, cutting or boring taking account of the properties of the material involved
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/062—Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam
    • B23K26/0622—Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam by shaping pulses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/20—Bonding
    • B23K26/21—Bonding by welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/20—Bonding
    • B23K26/32—Bonding taking account of the properties of the material involved
    • B23K26/324—Bonding taking account of the properties of the material involved involving non-metallic parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/38—Removing material by boring or cutting
    • B23K26/382—Removing material by boring or cutting by boring
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/38—Removing material by boring or cutting
    • B23K26/382—Removing material by boring or cutting by boring
    • B23K26/389—Removing material by boring or cutting by boring of fluid openings, e.g. nozzles, jets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/50—Working by transmitting the laser beam through or within the workpiece
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B32—LAYERED PRODUCTS
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    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B32B15/09—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/18—Layered products comprising a layer of metal comprising iron or steel
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14311—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles
    • B29C2045/14327—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles anchoring by forcing the material to pass through a hole in the article
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    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C2791/004—Shaping under special conditions
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

接合结构体(100、200)的制造方法是接合有第1构件(10、10a、10b、10c、10d、30)与第2构件(20)的接合结构体(100、200)的制造方法，且包括：将1脉冲包含多个子脉冲的激光照射至第1构件(10、10a、10b、10c、10d、30)的表面(13)，从而在第1构件(10、10a、10b、10c、10d、30)的表面(13)形成具有开口的穿孔部(11、11b、11c、11d、31)的工序；以及使第2构件(20)填充至第1构件(10、10a、10b、10c、10d、30)的穿孔部(11、11b、11c、11d、31)内并使其固化的工序。

Description

接合结构体的制造方法以及接合结构体
技术领域
本发明涉及一种接合结构体的制造方法以及接合结构体。
背景技术
以往，已知有接合有包含不同材料的第1构件及第2构件的接合结构体(例如参照专利文献1)。
在专利文献1中，公开了一种使树脂等异种材料接合于金属材料的接合方法。具体而言，通过对金属材料的表面呈交叉(cross)状地实施激光扫描(laser scanning)加工，从而在该表面形成多个突起(凹凸部)。并且，当将异种材料接合在形成有该突起的金属材料时，异种材料进入凹状部内，由此发挥锚固(anchor)效果，因此金属材料与异种材料的接合强度提高。
现有技术文献
专利文献
专利文献1：日本专利第4020957号公报
发明内容
发明所要解决的问题
然而，以往的接合方法中，当通过激光而在金属表面形成穿孔部(凹部)时，存在下述问题：难以相对于表面的开口直径而加深穿孔部，且难以提高接合强度。
本发明是为了解决所述问题而完成，本发明的目的在于提供一种能够实现接合强度的提高的接合结构体的制造方法以及接合结构体。
解决问题的技术手段
本发明的接合结构体的制造方法是接合有第1构件与第2构件的接合结构体的制造方法，且包括：将1脉冲包含多个子脉冲(sub pulse)的激光照射至第1构件的表面，从而在第1构件的表面形成具有开口的穿孔部的工序；以及使第2构件填充至第1构件的穿孔部内并使其固化的工序。
通过以此方式构成，利用1脉冲包含多个子脉冲的激光来形成穿孔部，由此，能够相对于表面的开口直径而加深穿孔部，因此能够实现接合强度的提高。
所述接合结构体的制造方法中，也可在穿孔部的内周面形成朝内侧突出的突出部。
所述接合结构体的制造方法中，第1构件也可为金属、热塑性树脂或热硬化性树脂。
所述接合结构体的制造方法中，第2构件也可为热塑性树脂或热硬化性树脂。
所述接合结构体的制造方法中，子脉冲的1周期也可为15ns以下。
所述接合结构体的制造方法中，1脉冲的子脉冲数也可为2以上且50以下。
本发明的接合结构体是通过所述的任一个接合结构体的制造方法而制造。
通过以此方式构成，利用1脉冲包含多个子脉冲的激光来形成穿孔部，由此，能够相对于表面的开口直径而加深穿孔部，因此能够实现接合强度的提高。
发明的效果
根据本发明的接合结构体的制造方法以及接合结构体，能够实现接合强度的提高。
附图说明
图1是本发明的第1实施方式的接合结构体的剖面的示意图。
图2是用于说明图1的接合结构体的制造方法的图，且是表示在第1构件上形成有穿孔部的状态的示意图。
图3是本发明的第2实施方式的接合结构体的剖面的示意图。
图4是用于说明图3的接合结构体的制造方法的图，且是表示在第1构件上形成有穿孔部的状态的示意图。
图5是表示实施例的第1构件通过激光而受到加工的状态的立体图。
图6是表示实施例的接合结构体的立体图。
图7是表示第1实施方式的第1变形例的第1构件的示意图。
图8是表示第1实施方式的第2变形例的第1构件的示意图。
图9是表示第1实施方式的第3变形例的第1构件的示意图。
图10是表示第1实施方式的第4变形例的第1构件的示意图。
具体实施方式
以下，参照附图来说明本发明的实施方式。
(第1实施方式)
首先，参照图1来说明本发明的第1实施方式的接合结构体100。
接合结构体100如图1所示，是接合有包含不同材料的第1构件10及第2构件20。在第1构件10的表面13，形成有具有开口的穿孔部11，在该穿孔部11的内周面，形成有朝内侧突出的突出部12。并且，第2构件20填充至第1构件10的穿孔部11内而固化。另外，图1是将第1构件10及第2构件20的接合界面放大而示意性地表示的图，实际上设有多个穿孔部11，但在图1中仅示出了一个。
第1构件10的材料为金属、热塑性树脂或热硬化性树脂，第2构件20的材料为热塑性树脂或热硬化性树脂。
作为所述金属的一例，可列举：铁系金属、不锈钢(stainless)系金属、铜系金属、铝系金属、镁系金属及它们的合金。而且，既可为金属成型体，也可为锌压铸(die-cast)、铝压铸、粉末冶金等。
作为所述热塑性树脂的一例，可列举：聚氯乙烯(Polyvinyl Chloride，PVC)、聚苯乙烯(Polystyrene，PS)、丙烯腈-苯乙烯(Acrylonitrile Styrene，AS)、丙烯腈-丁二烯-苯乙烯(Acrylonitrile Butadiene Styrene，ABS)、聚甲基丙烯酸甲酯(PolymethylMethacrylate，PMMA)、聚乙烯(Polyethylene，PE)、聚丙烯(Polypropylene，PP)、聚碳酸酯(Polycarbonate，PC)、改性聚苯醚(m-Polyphenylene Ether，m-PPE)、聚酰胺6(Polyamide6，PA6)、聚酰胺66(Polyamide 66，PA66)、聚缩醛(Polyacetal，POM)、聚对苯二甲酸乙二酯(Polyethylene Terephthalate，PET)、聚对苯二甲酸丁二酯(PolybutyleneTerephthalate，PBT)、聚砜(Polysulfone，PSF)、聚芳酯(Polyarylate，PAR)、聚醚酰亚胺(Polyetherimide，PEI)、聚苯硫醚(Polyphenylene Sulfide，PPS)、聚醚砜(Polyethersulfone，PES)、聚醚醚酮(Polyether Ether Ketone，PEEK)、聚酰胺酰亚胺(Polyamideimide，PAI)、液晶聚合物(Liquid Crystal Polymer，LCP)、聚偏二氯乙烯(Polyvinylidene Chloride，PVDC)、聚四氟乙烯(Polytetrafluorethylene，PTFE)、聚氯三氟乙烯(Polychlorotrifluroehtylene，PCTFE)及聚偏二氟乙烯(PolyvinylideneFluoride，PVDF)。而且，也可为热塑性弹性体(Thermoplastic Elastomer，TPE)，作为TPE的一例，可列举：热塑性聚烯烃(Thermoplastic Polyolefin，TPO)(烯烃系)、热塑性聚苯乙烯(Thermoplastic Ploystyrene，TPS)(苯乙烯系)、热塑性聚酯弹性体(Thermoplastic PolyEster Elastomer，TPEE)(酯系)、热塑性聚氨基甲酸酯(Thermoplastic Polyurethane，TPU)(氨基甲酸酯系)、热塑性聚酰胺(Thermoplastic Polyamide，TPA)(尼龙(nylon)类)及热塑性聚氯乙烯(Thermoplastic Polyvinyl Chloride，TPVC)(氯乙烯系)。
作为所述热硬化性树脂的一例，可列举：环氧树脂(Epoxy，EP)、聚氨基甲酸酯(Polyurethane，PUR)、脲甲醛(Urea Formaldehyde，UF)、三聚氰胺甲醛(MelamineFormaldehyde，MF)、酚甲醛(Phenol Formaldehyde，PF)、不饱和聚酯(UnsaturatedPolyester，UP)及硅酮(Silicone，SI)。而且，也可为纤维强化塑料(Fiber ReinforcedPlastics，FRP)。
另外，所述热塑性树脂及热硬化性树脂中，也可添加填充剂。作为填充剂的一例，可列举无机系填充剂(玻璃纤维(glass fiber)、无机盐类等)、金属系填充剂、有机系填充剂及碳纤维等
穿孔部11是平面观察呈大致圆形的非贯穿孔，在第1构件10的表面13上形成有多个。穿孔部11的表面13的开口直径R1优选为30μm以上且100μm以下。这是因为，若开口直径R1低于30μm，则有时第2构件20的填充性会发生恶化而锚固效果下降。另一方面是因为，若开口直径R1超过100μm，则有时每单位面积的穿孔部11的数量减少而锚固效果下降。
而且，穿孔部11的间隔(规定的穿孔部11的中心、和与规定的穿孔部11邻接的穿孔部11的中心的距离)优选为200μm以下。这是因为，若穿孔部11的间隔超过200μm，则有时每单位面积的穿孔部11的数量减少而锚固效果下降。另外，作为穿孔部11的间隔下限的一例，为穿孔部11重叠而不会压扁的距离。而且，优选的是，穿孔部11的间隔为相同。这是因为，若穿孔部11为等间隔，则剪切方向的接合强度成为各向同性。
此处，第1实施方式的穿孔部11是以扩径部111与缩径部112相连的方式而形成，所述扩径部111是在深度方向(Z方向)上从表面13侧朝向底部113而开口直径变大，所述缩径部112是在深度方向上从表面13侧朝向底部113而开口直径变小。扩径部111是以呈曲线状扩径的方式而形成，缩径部112是以呈曲线状缩径的方式而形成。
并且，扩径部111配置在表面13侧，并且缩径部112配置在底部113侧。因此，在穿孔部11中，扩径部111与缩径部112的边界部分的开口直径(内径)R2达到最大，开口直径R1小于开口直径R2。由此，突出部12配置在第1构件10的表面13侧。该突出部12例如是遍及周方向上的全长而形成，且形成为环状。
该穿孔部11是通过照射加工用的激光而形成。作为激光的种类，考虑到可进行脉冲振荡的观点，可选择纤维激光(fiber laser)、钇铝石榴石(Yttrium Aluminum Garnet，YAG)激光、钒酸钇(Yttrium orthovanadate，YVO4)激光、半导体激光、二氧化碳激光、准分子激光(excimer laser)，若考虑到激光的波长，则优选为纤维激光、YAG激光、YAG激光的二次谐波、YVO4激光、半导体激光。另外，激光的输出是考虑激光的照射直径、第1构件10的材料种类、第1构件10的形状(例如厚度)等来设定。例如，激光的输出上限优选为40W。这是因为，若激光的输出超过40W，则能量大而难以形成具有突出部12的穿孔部11。
而且，穿孔部11是通过照射1脉冲包含多个子脉冲的激光而形成。另外，作为出射此种激光的装置的一例，可列举欧姆龙(Omron)制造的纤维激光打标机(fiber lasermarker)MX-Z2000或MX-Z2050。具体而言，当对第1构件10照射激光时，第1构件10局部性地熔融，由此推进穿孔部11的形成。此时，激光包含多个子脉冲，因此熔融的第1构件10难以飞散而容易堆积在穿孔部11附近。并且，当穿孔部11的形成推进时，熔融的第1构件10堆积在穿孔部11的内部，由此形成突出部12。因此，通过突出部12，激光的反射波被封入在穿孔部11的内部，从而激光的加工进一步朝深度方向推进。即，容易使激光的能量集中在深度方向。其结果，在穿孔部11中，相对于表面的开口直径R1而深度变大。另外，激光的照射方向例如相对于表面13为垂直方向，穿孔部11的轴心相对于表面13成垂直。
如此，通过照射1脉冲包含多个子脉冲的激光，从而能够相对于表面的开口直径R1而增大穿孔部11的深度，因此锚固效果变大，能够实现接合强度的提高。进而，在热循环(cycle)环境下，即使产生因第1构件10及第2构件20的线膨胀系数差引起的剥离应力，也能够维持接合强度。即，能够实现热循环环境下的耐久性的提高。
另外，作为所述纤维激光打标机的加工条件，优选的是，子脉冲的1周期为15ns以下。这是因为，若子脉冲的1周期超过15ns，则会因导热而导致能量容易扩散，从而难以形成具有突出部12的穿孔部11。另外，子脉冲的1周期是一次子脉冲的照射时间、与从该子脉冲的照射结束直至下次子脉冲的照射开始为止的间隔的合计时间。
而且，作为所述纤维激光打标机的加工条件，优选的是，1脉冲的子脉冲数为2以上且50以下。这是因为，若子脉冲数超过50，则子脉冲的单位输出会变小，从而难以形成具有突出部12的穿孔部11。
并且，第2构件20被接合在形成有穿孔部11的第1构件10的表面13。该第2构件20例如通过射出成形、热板熔接、激光熔接、注模硬化、超声波熔接或振动熔接而接合于第1构件10。由此，第2构件20在填充至穿孔部11内的状态下固化。
此种接合结构体100例如可适用于使树脂罩(cover)(省略图示)接合在光电传感器(sensor)的金属壳体(case)(省略图示)的情况。此时，金属壳体相当于第1构件10，树脂罩相当于第2构件20。
接合结构体的制造方法
接下来，参照图1及图2来说明第1实施方式的接合结构体100的制造方法。
首先，如图2所示，对第1构件10的表面13照射1脉冲包含多个子脉冲的激光，由此，在第1构件10的表面13形成穿孔部11，并且在该穿孔部11的内周面形成突出部12。此时，若形成突出部12，则激光的反射波被封入在穿孔部11的内部，从而激光的加工进一步朝深度方向推进。由此，在穿孔部11中，相对于表面的开口直径R1而深度变大。
随后，向第1构件10的穿孔部11内填充第2构件20，并使该第2构件20固化。由此，第1构件10及第2构件20得以接合，形成接合结构体100(参照图1)。另外，第2构件20例如通过射出成形、热板熔接、激光熔接、注模硬化、超声波熔接或振动熔接而接合。
(第2实施方式)
接下来，参照图3来说明本发明的第2实施方式的接合结构体200。
接合结构体200如图3所示，是接合有包含不同材料的第1构件30及第2构件20。在第1构件30的表面33，形成有具有开口的穿孔部31，在该穿孔部31的内周面，形成有朝内侧突出的突出部32。并且，第2构件20被填充至第1构件30的穿孔部31内而固化。
第2实施方式的穿孔部31是以缩径部311、扩径部312及缩径部313相连的方式而形成，所述缩径部311是在深度方向(Z方向)上从表面33侧朝向底部314而开口直径变小，所述扩径部312是在深度方向上从表面33侧朝向底部314而开口直径变大，所述缩径部313是在深度方向上从表面33侧朝向底部314而开口直径变小。缩径部311是以呈直线状缩径的方式而形成，扩径部312是以呈曲线状扩径的方式而形成，缩径部313是以呈曲线状缩径的方式而形成。
并且，从表面33侧朝向底部314侧而依次配置有缩径部311、扩径部312及缩径部313。因此，在穿孔部31中，缩径部311与扩径部312的边界部分的开口直径(内径)R4小于表面33的开口直径R3及扩径部312与缩径部313的边界部分的开口直径R5。由此，突出部32配置在进入底部314侧的位置。该突出部32例如是遍及周方向上的全长而形成，且形成为环状。
另外，第1构件30的其他构成与所述的第1构件10同样。
接合结构体的制造方法
接下来，参照图3及图4来说明第2实施方式的接合结构体200的制造方法。
首先，如图4所示，对第1构件30的表面33照射1脉冲包含多个子脉冲的激光，由此，在第1构件30的表面33形成穿孔部31，并且在该穿孔部31的内周面形成突出部32。此时，若形成突出部32，则激光的反射波被封入在穿孔部31的内部，从而激光的加工进一步朝深度方向推进。由此，在穿孔部31中，相对于表面的开口直径R3而深度变大。
另外，第2实施方式中，与第1实施方式不同，突出部32配置在进入底部314侧的位置，但此种差异例如是起因于第1构件30的材料或激光照射条件等的差异。
随后，向第1构件30的穿孔部31内填充第2构件20，并使该第2构件20固化。由此，第1构件30及第2构件20得以接合，形成接合结构体200(参照图3)。另外，第2构件20例如通过射出成形、热板熔接、激光熔接、注模硬化、超声波熔接或振动熔接而接合。
实验例
接下来，参照图5及图6来说明为了确认所述第2实施方式的效果而进行的实验例1及实验例2。
[实验例1]
该实验例1中，制作与第2实施方式对应的实施例1～实施例4的接合结构体500(参照图6)与比较例1的接合结构体，并进行各自的接合评价。另外，作为接合评价，对未进行热冲击试验的测定接合强度，并且对热冲击试验后的测定接合强度，基于该测定结果来判定合格与否。将其结果示于表1。
[表1]
首先，对实施例1～实施例4的接合结构体500的制作方法进行说明。
实施例1～实施例4的接合结构体500中，使用SUS304作为第1构件501的材料。该第1构件501如图5所示，形成为板状，且长度为100mm，宽度为29mm，厚度为3mm。
并且，对第1构件501表面的规定区域R照射激光。该规定区域R是接合结构体500所接合的面积，设为12.5mm×20mm。实施例1～实施例4中共用的激光照射条件如下。
<激光照射条件>
激光：纤维激光(波长1062nm)
频率：10kHz
输出：3.8W
扫描速度：650mm/sec
扫描次数：20次
照射间隔：65μm
而且，如表1所示，在实施例1中，将子脉冲数设定为20，并且将子脉冲的1周期设定为15.0ns。在实施例2中，将子脉冲数设定为2，并且将子脉冲的1周期设定为15.0ns。在实施例3中，将子脉冲数设定为20，并且将子脉冲的1周期设定为10.5ns。在实施例4中，将子脉冲数设定为50，并且将子脉冲的1周期设定为15.0ns。
另外，频率是包含多个子脉冲的脉冲的频率。即，该照射条件中，一边在1秒钟内移动650mm，一边以65μm的间隔来照射1万次激光(脉冲)，该脉冲包含多个子脉冲。另外，扫描次数是激光对相同部位反复照射的次数。而且，实施例1、实施例2及实施例4中，1次子脉冲的照射时间为7.5ns，子脉冲的照射间隔为7.5ns。而且，实施例3中，1次子脉冲的照射时间为3ns，子脉冲的照射间隔为7.5ns。
如此，通过照射1脉冲包含多个子脉冲的激光，从而在第1构件501表面的规定区域R形成穿孔部，并且在该穿孔部内形成突出部。
并且，通过嵌入(insert)成型，将第2构件502接合在第1构件501的表面。实施例1～实施例4的接合结构体500中，使用PBT(赢泰聚合物(WinTech Polymer)制造的杜朗奈克斯(DURANEX)(注册商标)3316)作为第2构件502的材料。而且，成形机是使用日本制钢所制造的J35EL3。成形条件如下。
<成形条件>
预备干燥：120℃×5小时
模具温度：120℃
气缸(cylinder)温度：270℃
保压：100MPa
如此般制作实施例1～实施例4的接合结构体500。另外，第2构件502是形成为板状，且长度为100mm，宽度为25mm，厚度为3mm。
接下来，对比较例1的接合结构体的制作方法进行说明。
比较例1的接合结构体中，作为第1构件及第2构件的材料，使用与实施例1～实施例4相同的，并且成形条件也设定为相同。并且，在比较例1的接合结构体中，使用无脉冲控制功能的纤维激光而形成有穿孔部。即，通过照射1脉冲并非包含多个子脉冲的激光(单一脉冲)来形成穿孔部。因此，在比较例1的第1构件上，形成有研钵状(圆锥状)的穿孔部。
并且，对实施例1～实施例4的接合结构体500及比较例1的接合结构体进行接合评价。
另外，接合强度是使用英斯特朗(Instron)制造的机电式万能试验机5900来进行测定。具体而言，对于剪切方向，以5mm/min的拉伸速度来进行试验，在第2构件的破裂或接合界面的破裂时结束试验。并且，采用该试验中的最大强度来作为接合强度。
而且，热冲击试验是使用爱斯佩克(Espec)制造的冷热冲击装置TSD-100来进行。具体而言，将-40℃下的30分钟的低温暴露与85℃下的30分钟的高温暴露反复进行100次。
并且，为了判断热循环环境下的可靠性，依照以下的基准来判断合格与否。
合格(○)：“热冲击试验后的接合强度”/“热冲击试验前的接合强度”≥90％
不合格(×)：“热冲击试验后的接合强度”/“热冲击试验前的接合强度”＜90％
如所述表1所示，实施例1～实施例4的接合结构体500与比较例1的接合结构体相比，相对于表面的开口直径而穿孔部的深度变大。这是因为，在实施例1～实施例4的接合结构体500中，通过照射1脉冲包含多个子脉冲的激光，从而在穿孔部内形成突出部，因此激光的反射波被封入在穿孔部的内部，激光的加工进一步朝深度方向推进。
并且，实施例1～实施例4的接合结构体500与比较例1的接合结构体相比，在热冲击试验前后，接合强度变高。考虑这是因为，在实施例1～实施例4的接合结构体500中，相对于表面的开口直径而穿孔部的深度大，由此，锚固效果变大，接合强度提高。
进而判明，在实施例1～实施例4的接合结构体500中，即使在热冲击试验后也能够将热冲击试验前的接合强度维持90％以上。与此相对，比较例1的接合结构体中，在热冲击试验后，接合强度大幅下降。因此，如实施例1～实施例4的接合结构体500般，利用1脉冲包含多个子脉冲的激光来形成深的穿孔部，由此能够实现热循环环境下的耐久性的提高。
[实验例2]
该实验例2中，制作与第2实施方式对应的实施例5～实施例8的接合结构体与比较例2的接合结构体，并进行各自的接合评价。另外，接合评价是与实验例1同样地进行。将其结果示于表2。
[表2]
该实验例2中，变更第1构件的材料而区别于实验例1。具体而言，实验例2的接合结构体中，使用PPS(宝理塑料(Polyplastics)制的福特伦(FORTRON)(注册商标)1140)作为第1构件的材料。而且，伴随第1构件的材料变更，将实施例5～实施例8中共用的激光照射条件设为如下。
<激光照射条件>
激光：纤维激光(波长1062nm)
频率：10kHz
输出：1.1W
扫描速度：650mm/sec
扫描次数：3次
照射间隔：65μm
而且，如表2所示，在实施例5中，将子脉冲数设定为20，并且将子脉冲的1周期设定为15.0ns。在实施例6中，将子脉冲数设定为2，并且将子脉冲的1周期设定为15.0ns。在实施例7中，将子脉冲数设定为20，并且将子脉冲的1周期设定为10.5ns。在实施例8中，将子脉冲数设定为50，并且将子脉冲的1周期设定为15.0ns。
如所述表2所示，实施例5～实施例8的接合结构体与比较例2的接合结构体相比，相对于表面的开口直径而穿孔部的深度变大。这是因为，在实施例5～实施例8的接合结构体中，通过照射1脉冲包含多个子脉冲的激光，从而在穿孔部内形成突出部，因此，激光的反射波被封入在穿孔部的内部，激光的加工进一步朝深度方向推进。
并且，实施例5～实施例8的接合结构体与比较例2的接合结构体相比，在热冲击试验前后，接合强度变高。考虑这是因为，在实施例5～实施例8的接合结构体中，相对于表面的开口直径而穿孔部的深度大，由此，锚固效果变大，接合强度提高。
进而判明，在实施例5～实施例8的接合结构体中，即使在热冲击试验后也能够将热冲击试验前的接合强度维持90％以上。与此相对，比较例2的接合结构体中，在热冲击试验后，接合强度大幅下降。即，即使在将作为树脂的PPS用作第1构件的材料的情况下，利用1脉冲包含多个子脉冲的激光来形成深的穿孔部，由此能够实现接合强度的提高，并且能够实现热循环环境下的耐久性的提高。
(其他实施方式)
另外，此次揭示的实施方式在所有方面为例示，并不成为限定性解释的根据。因此，本发明的技术范围并非仅通过所述实施方式来解释，而是基于权利要求书的范围的记载来界定。而且，本发明的技术范围中包含与权利要求书的范围均等的含义及范围内的所有变更。
例如，第1实施方式中，表面13既可为平坦，也可为弯曲。另外，第2实施方式也同样。
而且，第1实施方式中，示出了以扩径部111与缩径部112相连的方式而形成的示例，但并不限于此，也可在扩径部与缩径部之间形成有沿深度方向笔直地延伸的部分。另外，第2实施方式也同样。
而且，第1实施方式中，示出了穿孔部11的周围为平坦的示例，但并不限于此，也可如图7所示的第1变形例的第1构件10a般，在穿孔部11的开口的周围形成有从表面13朝上方隆起的隆起部14。隆起部14是以围绕穿孔部11周围的方式而形成，平面观察时形成为大致圆形。该隆起部14例如是通过在照射1脉冲包含多个子脉冲的激光时，由熔融的第1构件10a堆积而形成。若如此般构成，则也通过隆起部14来产生锚固效果，因此能够进一步提高接合强度。另外，第2实施方式也同样。
而且，第1实施方式中，示出了穿孔部11的轴心相对于表面13为垂直的示例，但并不限于此，也可如图8所示的第2变形例的第1构件10b般，以穿孔部11b的轴心相对于表面13而倾斜的方式来形成。在穿孔部11b的内周面，形成有朝内侧突出的突出部12b。该穿孔部11b例如是通过使激光的照射方向相对于表面13而倾斜(45°以上且小于90°)来形成。由此，即使于在形成穿孔部11b的区域的上方存在照射激光时的障碍物的情况下，也能够形成穿孔部11b。另外，第2实施方式也同样。
而且，第1实施方式中，示出了在穿孔部11中形成有一个突出部12的示例，但并不限于此，也可如图9所示的第3变形例的第1构件10c般，在穿孔部11c中形成有多个突出部121c及突出部122c。该穿孔部11c例如可通过变更激光的输出条件，并将激光照射至相同部位而形成。若如此般构成，则穿孔部11c的表面积变大，并且通过形成多个突出部121c及突出部122c，能够进一步提高接合强度。另外，图9中，突出部为121c及122c这两处，但也可形成有三处以上。另外，第2实施方式也同样。
而且，也可如图10所示的第1实施方式的第4变形例的第1构件10d般，通过使位置错开的多次激光照射来形成一个穿孔部11d。即，也可通过使由激光照射所形成的穿孔部的一部分重叠而形成一个穿孔部11d。在穿孔部11d的内周面，形成有朝内侧突出的突出部12d。另外，第2实施方式也同样。而且，也可将所述第1变形例～第4变形例适当组合。
产业上的可利用性
本发明可利用在接合有包含不同材料的第1构件及第2构件的接合结构体的制造方法以及接合结构体。
符号的说明
10、10a、10b、10c、10d：第1构件
11、11b、11c、11d：穿孔部
12、12b、121c、122c、12d：突出部
13：表面
20：第2构件
30：第1构件
31：穿孔部
32：突出部
33：表面
100：接合结构体
200：接合结构体

Claims (7)

1.一种接合结构体的制造方法，其是接合有第1构件与第2构件的接合结构体的制造方法，所述接合结构体的制造方法的特征在于包括：
将1脉冲包含多个子脉冲的激光照射至所述第1构件的表面，从而在所述第1构件的表面形成具有开口的穿孔部的工序；以及
使所述第2构件填充至所述第1构件的穿孔部内并使其固化的工序。
2.根据权利要求1所述的接合结构体的制造方法，其特征在于，
在所述穿孔部的内周面，形成朝内侧突出的突出部。
3.根据权利要求1或2所述的接合结构体的制造方法，其特征在于，
所述第1构件为金属、热塑性树脂或热硬化性树脂。
4.根据权利要求1至3中任一项所述的接合结构体的制造方法，其特征在于，
所述第2构件为热塑性树脂或热硬化性树脂。
5.根据权利要求1至4中任一项所述的接合结构体的制造方法，其特征在于，
子脉冲的1周期为15ns以下。
6.根据权利要求1至5中任一项所述的接合结构体的制造方法，其特征在于，
1脉冲的子脉冲数为2以上且50以下。
7.一种接合结构体，其特征在于，其是通过根据权利要求1至6中任一项所述的接合结构体的制造方法而制造。
CN201580040009.8A 2014-08-22 2015-08-17 接合结构体的制造方法以及接合结构体 Pending CN106573342A (zh)

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